Module-1 Elements of Mechanical Engineering 20EME15

Introduction to Mechanical Engineering

Mechanical Engineering
• Mechanical engineering is an engineering branch that combines engineering physics and
mathematics principles with materials science to design, analyze, manufacture, and
maintain mechanical systems.
• It is one of the oldest and broadest of the engineering branches.
• Mechanical engineers are also involved with the design, construction and operations of all
kinds of machinery.

Role of Mechanical Engineering in Industries and Society

• The energy solution. Society of today badly needs more power. We have huge shortage of
electricity, especially in underdeveloped countries. Prices of fuel oil are going up. As a Mechanical
engineer you need to find a green way to generate power.
• The transportation solution. Millions of people die every year while traveling. Safety has
to be priority while designing new vehicles.
• Cost effective products. There are many who can't afford to buy basic things that are
required for day to day living. You need find better machines and processes that will reduce prices.
• Mechanical Engineering play very important roles in the industries like
Transportation, Medical, Agricultural, Defense, Power generation, Defense, and costruction

Contribution of Mechanical Engineering to the society

• Eliminates excessive usage of resources by optimizing and improving efficiency.
• To build things that make the world a better living place.
• Reduces human effort and makes work easy.

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Module-1 Elements of Mechanical Engineering 20EME15

Role of Mechanical Engineers in Manufacturing Industries

Mechanical engineer's responsibilities in any manufacturing industry are briefly as below.

• Designing a product: Based on market feedback and likely future trends. This involves
drawing preparation, prototyping, testing, design changes as per engineering / tool department's
feedback on manufacturability, tolerance stacking etc.

• Engineering of designed product: This involves selecting a manufacturing process (press

working, machining, molding, powder metallurgy, assembly, packaging, printing, painting, plating
etc.) and level of automation for every individual component of the product considering accuracy
and cost requirements

• Tooling: This involves design and manufacture of tools as per the process recommended
by engineering function. Tools again take in to consideration productivity. Material of tool
depending on accuracy, number of components required and cost.

• Manufacturing: This function has sub functions like planning, purchase, production,
warehousing.

• Quality control: QC function is responsible for ensuring quality and reliability. This
department mainly ensures that product is as per design and offers feedback to design.

• Maintenance: These guys take care that all machines and facilities like air conditioning,
plating plant are in working condition and the down time is lowest.

• Sales & marketing: These engineers are responsible for getting orders and keeping the
factory running. Marketing broadly does advertise and other sales promotion activities and sales
does the field work including after sales service

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Module-1 Elements of Mechanical Engineering 20EME15

Energy Sources and Power Plants:

Review of energy sources; Construction and working of Hydel power plant, Thermal power plant,
Nuclear power plant, Solar power plant, Tidal power plant, Wind power plant.

Energy
• Energy is defined as the capacity to do work
• Energy exists in various forms such as mechanical energy, electrical energy, thermal
energy and chemical energy.
• Energy in the process of transfer from one body to another. After it has been transferred,
energy is always designated according to its nature.
• Energy can be converted from one form to another in various ways but the total amount
of energy remains constant before and after the transformation.

Various sources of energy

The various sources of energy are
(i) Fossil fuels
(ii) Nuclear energy
(iii) Hydal energy
(iv) Solar energy
(v) Wind
(vi) Tides
(vii) Geothermal energy
(viii) Bio-mass

Different sources of energy

The sources of energy are classified in the following two ways:
(a) Conventional and non- conventional sources of energy
(b) Renewable and non-renewable sources of energy
Conventional energy sources
• Conventional sources of energy are the natural energy resources which are regularly used
for many years and are accepted as fuel to produce heat, light, food and electricity.
• The energy sources include firewood, fossil fuels

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Module-1 Elements of Mechanical Engineering 20EME15

• Fossil fuel is the greatest conventional source, wherein fossil implies the remains of plants
and animals, that got buried under the earth and transformed into rocks over the years.
These fossil fuels are coal, oil (petroleum), and natural gas.
• Conventional sources of energy are generally non-renewable sources of energy as the
accumulation or creation of conventional sources of energy takes years, once they are
exploited or consumed.

Non-conventional energy sources

• An alternative to conventional sources of energy is the non-conventional sources of
energy, that achieved popularity in recent years.
• The energy can be obtained from various sources such as the sun, wind, biological wastes,
hot springs, tides, etc. to generate heat and power.
• These are not only renewable sources of energy but are also pollution free. These sources
are present in abundance in nature, and they are constantly generated, so it cannot be
exhausted easily, and used again and again.

Difference between Conventional and non- conventional sources of energy

Conventional sources of energy Non- conventional sources of energy
These are widely used and economical These are rarely used and initial cost is high
Most of them are exhaustible Most of them are in-exhaustible
Most of them are pollute the environment Most of them are environment friendly
They are reliable (continuous supply of energy They are not reliable (continuous supply of
is possible) energy is not possible)
Energy transmission cost is high Energy transmission cost is low
Example: Fossil fuels, Hydel energy Example: solar, wind, tidal etc.

Renewable and non-renewable sources of energy

Renewable sources of energy
The renewable sources of energy are defined as the energy sources which are continuously
produced in nature and are essentially inexhaustible or non-depletable. These energy sources
replenish themselves naturally in a relatively short time and therefore will always be available.
E.g. of renewable energy sources: direct solar energy, wind energy, tidal energy, hydel
energy, ocean thermal energy, bio energy, geothermal energy, peat, fuel wood, fuel cells, solid
wastes, hydrogen energy etc.

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Module-1 Elements of Mechanical Engineering 20EME15

Non-renewable sources of energy

The non-renewable energy sources are those natural resources that are available in limited
quantity and these resources cannot be renewed in short durations.
E.g. Fossil fuels (coal, petroleum and petroleum products), nuclear fuels and heat traps
.

Difference between Renewable and non-renewable sources of energy

Renewable sources of energy Non- Renewable sources of energy
These are in-exhaustible These are exhaustible
Freely available and environment friendly Not freely available & hazardous to
environment
Initial cost is high but maintenance cost is low Initial cost is low but maintenance cost is
high
Energy concentration varies from region to Energy concentration almost same in all
region region
Example: solar, hydel, wind, tidal etc. Example: Fossil fuels, nuclear fuels.

Hydel Power Plant

Figure. Hydro-power station

Hydro energy is considered as an indirect source of solar energy. The water from the earth’s
surface gets evaporated by solar heat and forms as clouds, this intern results in rainfall. The rain
water flowing as river can be stored in dam and released in a regulated way to through a penstock,
to drive the turbine. The potential energy of water stored at a height is converted into mechanical
Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore
Module-1 Elements of Mechanical Engineering 20EME15

energy in water turbines. The mechanical energy produced by the water turbines is further
converted into electrical energy by the electric generators which are coupled to the water turbines.
After doing the useful work the water is discharged from the turbine to the river through a water
way to the tail race through draft tube.
Merits
i) These can be used for power generation in large scale
ii) Environmental friendly source of energy
iii) As water is natural resource, it is the energy available at free of cost
Demerits
i) It is expensive to build a dam
ii) By construction of dam, the nearby area may be flooded and this could affect nearby
wildlife and plants
iii) During summer the water may not be sufficient to produce electricity
Applications
i) To generate electricity in power plants
Wind Power Plant

Figure. Schematic diagram of Wind Mill and Wind Power plant

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

Wind arise primarily from temperature difference of the earth’s surface resulting from
unequal exposure to (or absorption of) solar radiation. Wind possesses kinetic energy. The kinetic
energy of wind can be converted into mechanical energy that can be utilized to perform useful
work or to generate electricity. Wind energy conversion devices are commonly known as wind
turbines.
It consists of a rotor hub fitted with large sized blades. When the wind blows against the
blades of a wind turbine, rotational motion is caused in the wind turbine. Thus, the kinetic energy
of wind is converted into mechanical work. This mechanical work can be used directly to run a
machine or to run a generator to produce electricity. Wind energy can be utilized in places wind
velocity is considerably high. An ideal wind speed that can be utilized to extract energy lies
between a speed 10 km/hr to 50 km/hr.

The speed increasing device (gearbox) converts relatively slow rotation of the spinning
blades into higher speed motion turning the drive shaft quickly enough to power the electricity
generator. The tail fin is used for automatic wind source steering.

Advantages
• Wind is a reliable and infinite renewable energy resource
• Wind energy is cost effective, and prices are dropping still
• Wind energy reduces carbon emissions when used instead of fossil fuels
• Simple equipments and easy operation

Disadvantages
• Wind energy can be unpredictable as the amount of electricity generated is dependent on the
speed and direction of the wind
• Wind farms can affect the visual appearance of the landscape
• Wind turbines can damage the habitats of birds and marine life.
• Wind farms can be expensive to construct

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

Solar Energy
Solar energy refers to the energy produced and radiated by the sun, i.e. sun’s energy which
reaches the earth. Solar energy can be converted directly or indirectly into other forms of energy,
such as heat and electricity which can be utilized by man. The heat energy contained in the rays
of the sun is absorbed by a black surface.
The solar energy can be converted into other forms of energy, the primary processes are
i) Heliochemical process: conversion of solar energy into chemical energy
ii) Helioelectrical process: conversion of solar energy into electrical energy
iii) Helioithermal process: conversion of solar energy into thermal energy

Solar Panels
• It is the heart of the solar power plant.
• Solar panels consist a number of solar cells.
• The energy produced by each solar cell is very small, but combining the energy of them
we will get enough energy to charge a battery

2.Solar Cells

It is the energy generating unit, made up of p-type and n-type silicon semiconductor. It’s the heart
of solar power plant.

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Module-1 Elements of Mechanical Engineering 20EME15

3. Battery

Batteries are used to produce the power back or store the excess energy produced during day, to
be supplied during night.

4. D.C. to A.C. Converter (Inverter)

Solar panels produce direct current which is required to be converted into alternating current to
be supplied to homes or power grid

Working of Solar Power Plant

• As sunlight falls over a solar cell, a large number of photons strike the p-type region
of silicon.
• Electron and hole pair will get separated after absorbing the energy of photon.
• The electron travels from p-type region to n-type region due to the action of electric
field at p-n junction.
• Further the diode is reversed biased to increase this electric field.
• So, this current starts flowing in the circuit for individual solar cell. We combine
the current of all the solar cells of a solar panel, to get a significant output

Advantages of Solar Energy

• Most clean and renewable source of energy.
• It is available in abundance and endless.
• It provides electricity at low cost, as fuel is free.
• With new research in this sector we now have a good power storage solution.
• Keeping in mind the pollution and cost of fossil fuel, it’s becoming the most reliable
source of clean energy
Disadvantages of Solar Power Plant

• It requires a lot of land to be captured forever.

• Initial cost of installation is too high.
• The energy storage options are not efficient and moreover costly if efficient.
• Power production is quite low as compared to nuclear or other resources to produce power.
• There is a problem if it is cloudy for few days.

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

Application of solar energy

i) Generating electricity using photovoltaic cells

ii) Water pumping and lighting
iii) Water distillation purpose in the coastal areas
iv) Solar furnaces
v) Heating the water domestic and industrial purposes
vi) Source of energy for satellites in the space

Thermal Power Plant

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

Nuclear Power Plant

Nuclear energy is the energy released during nuclear fission or fusion, especially when
used to generate electricity. Nuclear fuel is any material that can be consumed to derive nuclear
energy. The most common type of nuclear fuel is fissile elements that can be made to undergo
nuclear fission chain reactions in a nuclear reactor. The most common nuclear fuels are 235U and
239Pu.

Figure. Nuclear Energy Conversions

The basic nuclear generating station energy cycle is shown in Figure. Fuel containing
fissile material (Uranium) is fed to the reactor where fission takes place. The energy liberated
appears in the form of heat, which is used to boil water in heat exchanger or steam generator. The
steam produced from the boiling water spins a turbine-generator set, where the heat is converted
first to kinetic energy and then it will converts to mechanical energy in the turbine and to
electricity by the generator.

Application of Nuclear energy

i) Generate electricity in nuclear power stations
ii) Military operations in developing nuclear weapons
iii) Medical field for radiotherapy, sterelization of medical products
iv) Food preservation and agricultural fields

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module-1 Elements of Mechanical Engineering 20EME15

MODULE-I
Steam

Formation of Steam

Figure 1. Formation of Steam

tsup = Superheated temperature

Figure 2. Temperature – Enthalpy diagram

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 Module-1 Elements of Mechanical Engineering 20EME15

Steam is water in the gas phase, which is formed when water boils or evaporates, the generators
known as boilers. Water will be taken at atmospheric pressure and temperature and converted into
steam by the application of heat. As the steam continuously generated, its pressure gradually
increases and is supplied from boilers to the engines or turbines at constant pressure.

The process of generation of steam can be represented through a temperature – enthalpy

diagram as shown in the figure 2.
Consider 1 kg of water at 00 C taken in a cylinder with a pressure P applied by a weight
‘w’ on a free frictionless piston as shown in the figure 1(i). When it is heated keeping the pressure
constant, its volume increases with increase of temperature, until it reaches a point B in the graph
(figure 2) when steam begins to form. This temperature (ts) at which steam begins to form is called
the saturation temperature. The saturation temperature is different for different pressures and it
increases with rise of pressure. The saturation temperature at atmospheric pressure of 1 bar is
1000 C.
Further addition of heat, initiates the evaporation of water while the temperature remains
at the saturation temperature because the water will be saturated with heat and any further addition
of heat changes only the phase from the liquid phase to gaseous phase. When steam begins to
form at saturation temperature, some water particles may be present in it figure1(iii). If the steam
contains water particles in suspension, it is called wet steam. This evaporation will be continued
at the same saturation temperature until the whole water is completely converted into steam as
shown in figure 1 (iv). This point is represented by point C on the graph (figure 2). At the
saturation temperature if the steam contains no water particles, it is dry saturated steam. This
constant pressure and temperature heat addition process is represented by horizontal line BC on
the graph (figure 2).

If the dry saturated steam is further heated beyond point ‘C’ (figure 2), at the same
pressure the temperature of steam rises above the saturation temperature. The steam which is at a
temperature greater than saturation temperature is called superheated steam. This superheating
is represented by the inclined line CD on the graph (figure 2).

Thus, during the formation there are three states of steam namely wet steam, dry steam
and superheated steam.

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 Module-1 Elements of Mechanical Engineering 20EME15

Different Stages of Steam

The steam generated can exist in three forms
i) Wet steam
ii) Dry saturated stem
iii) Superheated steam

Wet Stem
Wet steam is defined as two phase mixture of entrained water molecules and stem in thermal
equilibrium at saturation temperature corresponding to a given pressure.

Dry saturated stem

A saturated steam at the saturation temperature corresponding to a given pressure and having no
water molecules entrained in it is defined as dry saturated steam

Superheated Steam
When a dry saturated steam is heated further at the given constant pressure, its temperature rises
beyond its saturation temperature. The steam in this state is said to be superheated.

Dryness fraction
Dryness fraction of steam is defined as the ratio of mass of dry steam actually present in a wet
steam to the total mass of wet steam”.
Mass of dry steam in wet steam
Dryness fraction, x =
Total mass of wet steam
mg
x=
mf + mg
Where, mg — Mass of dry steam.
mf — Mass of suspended water molecules. (x should always be less than 1)

Enthalpy of Steam
Enthalpy is defined as the sum of internal energy and product of pressure and volume.
h = U + PV

(i) Enthalpy of Water:

The total amount of heat required to raise the temperature of 1 kg of water which is initially at 00
C to its saturation temperature, at a given constant pressure is called the enthalpy of water. It is
also called sensible heat. It is denoted by ‘hf’ and expressed in ‘kJ / kg’.

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 Module-1 Elements of Mechanical Engineering 20EME15

(ii) Enthalpy of Evaporation:

The total amount of heat required to convert 1 kg of water which is initially at its saturation
temperature to dry saturated steam at the same saturation temperature and at the given constant
pressure is called enthalpy of evaporation. It is also called the latent heat of vaporization of steam.
It is denoted by ‘hfg’ and is expressed in ‘kJ / kg’.

(iii) Enthalpy of dry saturated steam:

The total amount of heat required to generate 1 kg of dry saturated steam from 1 kg of water
which is initially at 00 C and at a given constant pressure is called the enthalpy of dry saturated
steam. It is denoted by ‘hg’ and expressed in ‘kJ / kg’. Enthalpy of steam is equal to the sum of
enthalpy of water (hf) and enthalpy of evaporation (hfg).
Thus it can be expressed as hg = hf + hfg kJ / kg

(iv) Enthalpy of Wet Steam:

Enthalpy of wet steam is defined as the “total amount heat of required to generate 1 kg of water
which is initially at 0˚C to 1 kg of wet steam at the specified dryness fraction”. It is denoted by
‘hw’ and expressed in ‘kJ / kg’
Enthalpy of wet steam, hw = hf +x hfg kJ / kg
Where, x = dryness fraction of steam

(v) Enthalpy of Superheated Steam:

The total amount of heat required to generate 1 kg of superheated steam at the stated superheated
temperature from 1 kg of water which is initially at 00 C and at a given constant pressure is called
the enthalpy of superheated steam. It is denoted by ‘hsup’ and expressed in ‘kJ / kg’.
It can be determined by using the equation
hsup = hg + Cp (tsup – ts) kJ / kg
The difference between the superheated temperature (tsup) and the saturation temperature (ts) is
called the degree of superheat.

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 Module-1 Elements of Mechanical Engineering 20EME15

Specific Volume
The volume of a unit mass of steam at a given pressure is called the specific volume of steam. It
is expressed in m3 / kg.
As steam exists in three states, the specific volume is considered for all the three states.

(i) Specific volume of saturated steam:

It is defined as the volume occupied by 1 kg of water at saturation temperature at a given pressure.
It is denoted by vf

(ii) Specific volume of dry saturated steam:

It is defined as the volume occupied by 1 kg of dry saturated steam at a given pressure. It is
denoted by ‘Vg’ and expressed in ‘m3 / kg’.

(ii) Specific volume of wet steam:

Wet steam contains two phase mixture of saturated water and vapour. Hence specific volume of
wet steam is defined as the volume occupied by the saturated water and vapour at a given pressure.
It is denoted by ‘Vw’ and expressed in ‘m3 / kg’.
Wet steam consists of saturated liquid in suspension. If in 1 kg of wet steam there is ‘x’
kg of dry steam, then ‘(1 – x)’ kg will be the saturated liquid. Therefore, specific volume of wet
steam vw = xvg + (1–x) vf m3/ kg
Since ‘(1–x) vf’ is too small quantity it is neglected. Hence
Specific volume of wet steam, Vw = xVg m3 / kg

(iii) Specific volume of the superheated steam: It is defined as the volume occupied by 1kg of
superheated steam at a given pressure and superheated temperature. It is denoted by ‘Vsup’ and
expressed in ‘m3 / kg’
Since superheated steam behaves like a perfect gas, its specific volume can be
determined by using Charles law as follows:
vg v sup
=
Ts T sup
T sup
V sup = Vg
Ts
where, vg —Specific volume of dry saturated steam at pressure ‘p’
Ts —Saturation temperature, K
Tsup —Specified superheated temperature, K
vsup — Specific volume of superheated steam at pressure ‘p’

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 Module-1 Elements of Mechanical Engineering 20EME15

Density of Steam
It is the mass of steam per unit volume of steam at a given pressure and temperature. It is the
reciprocal of specific volume.

Density of Wet steam = ρw = 1/ xVg

Density of dry steam = ρg = 1/ Vg

Density of superheated steam = ρsup= 1/ Vsup

Internal Energy of Steam

When water vaporizes and gets converted into steam there is a considerable increase in its volume.
Thus some amount of external work is done during vaporization. This external work can be
expressed as product of pressure and volume of steam. Thus the external work done, for the three
states of steam are as follows:
PVg for dry saturated steam
PVw for wet steam
PVsup for superheated steam
Internal energy of steam is the actual energy stored in steam which can be utilized for
doing external work. It is equal to the difference between the total heat of steam and the external
work done during vaporization. It is denoted by ‘U’ and expressed in ‘kJ / kg’. Thus,
Internal energy of dry saturated steam : Ug = hg – 100 PVg kJ / kg
Internal energy of wet steam : Uw = hw –100 PVw kJ / kg
Internal energy of superheated steam : Usup = hsup – 100PVsup kJ / kg
Where ‘p’ is in bars

Department of Mechanical Engineering, Acharya Institute of Technology, Bangalore

Module 2- Boilers, Turbines and Hydraulic Pumps Elements of Mechanical Engineering (18ME15/25)

HYDRAULIC TURBINES
Introduction
A prime mover is self-moving device which converts the available natural source of energy
into mechanical energy of motion to drive the other machines. The various types of prime
movers which convert heat energy produced by the combustion of fuels into mechanical energy
are: steam engines, steam turbines, gas turbines and internal combustion engines.
A hydraulic turbine or water turbine is a hydraulic prime mover that converts the energy of
falling water into mechanical energy in the form of rotation of shaft. The mechanical
energy in turn is converted into electrical energy by means of an electric generator.

Classification of Water Turbines

Water turbines classified based on the following factors:

1. Type of energy available at the inlet of the turbine

a) Impulse turbine- The energy available at the inlet of the turbine is only kinetic energy.
Example- Pelton Wheel.
b) Reaction turbine- Both pressure energy and kinetic energy is available at the inlet of
the turbine. Example- Kaplan turbine, Francis turbine.
2. Head at the inlet of the turbine
a) High head turbine- Head of water available at the inlet of the turbine ranges from
several hundred meters to a few thousand meters. Example- Pelton wheel.
b) Medium head turbine- Head of water available at the inlet of the turbine ranges from
50 mts to 400 mts. Example- Francis turbine.
c) Low head turbine- Head of water at the inlet will be less than 50 mts. Example- Kaplan
turbine.
3. Based on the direction of flow of water through the runner.
a) Tangential flow turbine- Water flows along the tangent to the runner. Example- Pelton
wheel.
b) Axial flow turbine- Water flows in a direction parallel to the axis of rotation of the
runner. Example- Kaplan turbine.
c) Radial flow turbine- Water flows in a radial direction through the runner. Example-
Old Francis Turbine.
d) Mixed flow turbine- Water flows radially into the runner and leaves axially. Example-
Modern Francis turbine.

Specification of Hydraulic Turbine

Hydraulic Turbines are specified by the following criteria:
1. Water head
2. DC/AC power rating
3. Efficiency and working life of power generator
4. Dimensions related to height, weight, length and width.

Department of Mechanical Engineering, AIT, Bengaluru – 107 10

Module 2- Boilers, Turbines and Hydraulic Pumps Elements of Mechanical Engineering (18ME15/25)

Pelton Wheel
The Pelton wheel is the most commonly used type of impulse turbine. It works under high head
and requires small quantity of water. Figure 3 shows a schematic sketch of a Pelton wheel. The
water from a high head source is supplied to the nozzle provided with a needle, which controls
the quantity of water flowing out of the nozzle. The pressure energy of water is converted into
velocity energy as it flows through the nozzle. The jet of water is issuing out of the nozzle at
high velocity impinges on the curved blades known as Pelton cups, at the centre as shown in
the adjoining figure.

The impulsive force of the jet striking on the Pelton cups sets up the Pelton wheel to rotate in the
direction of the impinging jet. Thus the pressure energy of the water is converted into
mechanical energy. The pressure inside the casing of the turbine will be at atmospheric pressure.

Figure 3: Pelton Wheel

Department of Mechanical Engineering, AIT, Bengaluru – 107 11

Module 2- Boilers, Turbines and Hydraulic Pumps Elements of Mechanical Engineering (18ME15/25)

Francis Turbine
The Francis turbine is a medium head reaction turbine in which water flows radially
inwards. Figure 4 shows a simple schematic representation of the Francis turbine. It consists
of a spiral casing enclosing a number of stationary guide blades fixed all around the
circumference of an inner ring of moving vanes forming the runner which is keyed to the
turbine shaft.

Water at high pressure enters through the inlet in the casing and flows radially inwards to the
outer periphery of the runner through the guide blades. From the outer periphery of the runner
the water flows inwards through the moving vanes and discharges at the centre of the runner
at lower pressure.

During its flow over the moving blades it imparts kinetic energy to the runner to set it into
rotational motion. To enable the discharge of water at lower pressure, a diverging conical
tube called draft tube is fitted at the centre of the runner. The other end of the draft tube is
immersed in the discharging side of the water known as tail race.

Figure 4: Francis Turbine

Department of Mechanical Engineering, AIT, Bengaluru – 107 12

Module 2- Boilers, Turbines and Hydraulic Pumps Elements of Mechanical Engineering (18ME15/25)

Kaplan Turbine
The Kaplan turbine is a low head, reaction turbine in which water flows axially. Figure 5
shows a simple schematic representation of a Kaplan turbine. All the parts of turbine are
similar to that of the Francis turbine except the runner and the draft tube. The runner of the
Kaplan turbine resembles with the propeller of the ship, hence sometimes the Kaplan
turbine is also called propeller turbine.

The water at high pressure enters the turbine casing through the inlet and flows over the guide
blades. The water from the guide blades strikes the runner blades axially imparting the
kinetic energy to set it into rotational motion. The water discharging at the centre of the
runner in the axial direction into the draft tube which is in L- shape having its discharging
end immersed into the tail race.

Figure 5: Kaplan Turbine

Department of Mechanical Engineering, AIT, Bengaluru – 107 13

Module-1 Elements of Mechanical Engineering(20EME15)

HYDRAULIC PUMPS

Introduction to Hydraulic Pumps

• A Hydraulic pump is a device that transfers energy to raise liquid from a lower level
to a higher level, or circulate a liquid in a closed system.
• Typical examples of a pump include, pumping of water from a sump to an overhead tank,
or circulating a coolant or lubricant oil to various moving parts of a machine.
• Pumps are especially used in pumping water for agriculture and irrigation works,
municipal water works and drainage system, in steam power plants for condensing water,
condensate feed water into the boiler drum, circulate liquid in machine tools etc.

Classification of pumps
A simple classification of pump is briefed as follows:
1. Centrifugal pump, which makes use of the centrifugal force of a Rotary element
known as impeller to impart energy to the liquid.
2. Reciprocating pump, which imparts energy to the liquid by the reciprocating action
of the Piston or plunger inside the cylinder.
3. Rotary Pump, which consists of rotating members, traps fluid in its closed casing
thereby building and raising the pressure of the fluid and in turn discharges the high-
pressure fluid. The rotating members may be gears, Vanes, or screws.

Centrifugal Pump

Centrifugal pump makes use of the centrifugal force of a rotary element known as impeller to
impart energy to the liquid. It is the most widely used hydraulic pump for various applications.
Construction Impeller is the principle rotating part of the pump. It is a wheel provided with
a series of backward curved blades (vanes). The impeller is mounted on a shaft, which is
connected to the shaft of the electric motor. Volute casing is an airtight chamber surrounding the
impeller it is designed with its cross section gradually increasing so that the velocity of the flow
decreases resulting in an increase in the pressure of the fluid.

Dept. of Mechanical Engg. Acharya Institute of Technology, Bengaluru

Module-1 Elements of Mechanical Engineering(20EME15)

Suction pipe is a circular pipe with its upper end connected to the centre of the impeller, which is
known as eye of the impeller. The lower end of the suction pipe is immersed in the sump or
reservoir from where the liquid is to be lifted up. The lower end of the suction pipe is fitted with
a foot valve and a strainer as shown in the figure. The strainer avoids the entry of any foreign
material into the suction pipe, while the foot valve is a non-return or one-way valve that opens
only in the upward direction so as to prevent the suction pipe draining out when the pump is
stopped. The foot valve also helps in priming of the pump.
Delivery pipe is also a circular pipe with its lower end connected to the outlet of the pump while
the upper end is connected to the tank, where the liquid is to be pumped or stored. In the delivery
pipe, a control valve known as delivery valve is provided for regulating the fluid flow. The
delivery valve is closed prior to starting and stopping the pump in order to prevent any possible
black flow from the delivery pipe and consequent damage to the pump assembly.

Operation

In operation, when the electric motor is switched-on, the impeller rotates creating a suction at the
suction pipe. Due to suction created, the water from the sump starts flowing into the casing
through the eye of the impeller. The centrifugal force created by the rotating impeller acts on the
water causing it to flow radially outward and towards the outlet of the casing. As the water flows
through the casing, its velocity reduces due to the increasing cross-sectional area of the casing.
The decrease in velocity increases the pressure of the water flowing through the casing. The

Dept. of Mechanical Engg. Acharya Institute of Technology, Bengaluru

Module-1 Elements of Mechanical Engineering(20EME15)

pressure reaches to the maximum at the outlet of the pump. The water flows through the delivery
pipe into the overhead tank. It is important to note that when the fluid is discharged to the
delivery, a partial vacuum is created near the eye of the impeller, which in turn causes the liquid
from the sump which is at atmospheric pressure to rush through the suction pipe to replace the
fluid that is being discharged. Thus, the water is pumped continuously from the sump to the tank
through the delivery pipe

Advantages of centrifugal pump

1. Suitable for all types of fluids.

2. Simple and compact

3. Delivers uniform flow. Output flow is study and consistent.

4. Can be mounted horizontally or vertically.

5. Easy maintenance.

Disadvantages of centrifugal pump

1. Relatively poor suction power. When the pump end is dry, the rotation of the impeller, even at
high speeds is not sufficient to lift liquid into the pump. The pump must be primed before
pumping can begin.
2. Develops cavitation resulting in structural failure of impeller blades.
3. Not suitable for air or gases.
4. Magnetic resonance in centrifugal pump results in small loss of energy.
Applications of centrifugal pump
Centrifugal pumps are the most common type of pump used in industry, agriculture, municipal
(water and waste water plants), power generation plants, petroleum and many other industries.

Dept. of Mechanical Engg. Acharya Institute of Technology, Bengaluru