Module 1

Introduction & Power Plants

 Introduction to Mechanical Engineering (Overview only):
Role of Mechanical Engineering in Industries and
Society- Emerging Trends and Technologies in different
sectors such as Energy, Manufacturing, Automotive,
Aerospace, and Marine sectors.
 Steam Formation and Application: Modes of heat
transfer, Steam formation, Types of steam, Steam
properties and applications of steam.
 Power Plants: Basic working principles of hydel power
plant, steam power plant, nuclear power plant, Tidal
power plant and Wind power plant.
Self-Study Components: Photovoltaic cells
Role of Mechanical Engineering in Industries and Society

A Mechanical Engineer creates/designs and manufactures

components/structures/machines/vehicles useful for mankind. An engineer is responsible for
feasibly and optimally utilizing available sources of energy and converting it into useful
products, or processes or services. Mechanical engineering plays a critical role in
manufacturing from pins to rockets. lt enables us to do many daily activities with ease and
efficiency. Mechanical engineers work in various manufacturing industries, in building and
designing nuclear plants, automobiles, railway equipment, spacecraft, etc. These mechanical
engineers are sometimes called nuclear engineers, automotive engineers, railway engineers,
and aerospace engineers.

Mechanical Engineers play a vital role in the sustainable development of industry and
society. Starting from the conceptualization of the product to the design, manufacturing,
sales, and service to the end of life of a product. Studying the design, laying out the tooling
for the production and optimizing the raw material consumption in the manufacturing
component requires huge skills.

Mechanical Engineer also plays a vital role in logistics. Procuring the materials for the
production, maintaining the adequate material in the stores, dispatching the finished
products to the Consumer is the role of a Logistic Engineer. Mechanical Engineer also works
as a safety Engineer in an Industry. Taking care of the human resources, machinery,
equipment and planning out the safer working conditions and ensuring the safety of the
operations is the responsibility of the safety engineer.

Mechanical Engineer plays a vital role in the overall growth of the economy as well as
the Society. Designing a product for longer product life cycle and reutilization/ recycling the
product reduces the dependency of the materials by the industry. Also, developing newer
equipment and devices for harnessing renewable sources energy reduces the dependencies
on fossil fuels. This in turn contributes to green energy, low or no emission of carbon and its
compounds
Following are few of the areas where in Mechanical Engineer play his role in an industry:
Design Engineer, Production Manager, Safety Engineer, QA Engineer, Logistic Manager, Data
analyst, Sales Executive/Manager, HRM, etc.,

Emerging trends and technologies in different sectors

Marine

Energy
Renewable
Storage

Emerging Trends
& Technologies

Manufacturing Aerospace

Automotive

Trends in Renewable Energy: Renewable is one of the emerging trends in the energy sector.
This Renewable energy trend helps to safeguard the environment by emitting little to no
harmful pollutants. The fundamental premise of renewable energy is to obtain it from a
consistent source in the environment, such as the sun, wind, or geothermal sources. The
source is then converted into useful power or fuel. A variety of technologies that address
various facets of generating power and heat from renewable sources is one of the latest
technology trends in renewable energy. This involves lowering the cost of building
renewable infrastructure and
enhancing the efficiency of power generation. Sources available in Sun, Wind, Tides, etc are
utilized for useful power generation & other works.

Aerospace Sector: Aerospace collectively refers to the atmosphere and outer space; it's a
diverse industry with a multitude of commercial, industrial, and military applications.
Aerospace engineering consists of aeronautics (Building and flying aircraft) and astronautics
(Space travel and exploration) and the research, design, production, operation, or
maintenance of aircraft and spacecraft. The trending sectors in Aerospace engineering
technology are.
1. Zero-Fuel Aircraft
2. Structural Health Monitoring (SHM)
3. Advanced Materials
4. Smart Automation and Block chain
5. Additive Manufacturing (3D Printing)
5. Supersonic Flights
7. More Resilient and Dynamic Aerospace & Defense (A&D) Supply Chains
8. Artificial intelligence (Al)
10. Autonomous Flight Systems

Automotive Sector: Electric and Autonomous vehicles are the two important areas witnessed
nowadays. The automotive industry has been experiencing a great deal of change. More
software is being added to vehicles, along with a greater number of electric and autonomous
vehicles are in production and on the road.
Some of the most common automotive trends are.
• A Greater Amount of Al/Machine Learning and Connectivity
• An increase ln Electric and Autonomous Vehicles
• Software Security Has Become a Top Concern
• Electrification
• Human-Machine-interface

Manufacturing Sector: Robotics and 3-D, 4-D printing are the domains which are in demand.
Al, robots,3Dprinting and the like are all the latest manufacturing trends in manufacturing.
Technology. Robots on the factory floor are growing at warp speed, thanks to their declining
cost and increasing capabilities.

Energy Storage: Energy systems offer a diverse set of technological solutions for improving
power supply methods like batteries, thermal, mechanical and hydrogen energy. Energy
storage is one of the effective energy industry emerging trends. Energy storage permits
steady pricing by proactively maintaining demand from consumers. ln response to shifting
energy demands and technological advancements, the energy storage business has evolved,
adapted, and innovated during the last century. Energy storage systems offer a diverse set of
technological solutions for improving the power supply to build more resilient energy
infrastructure and save money for utilities and customers.
Energy storage methods can be classified into five categories based on their technology.
• Batteries
• Thermal
• Mechanical
• Pumped hydro
• Hydrogen
It has the potential to save consumers money while also improving dependability and
resilience, integrating power sources, and reducing environmental impacts.

Marine sector: Advances in ship building and propulsion are the areas in the Marine sector
which demands more focus currently. Advances in shipbuilding, propulsion, smart shipping,
advanced materials, big data and analytics, robotics, sensors, and communications in
conjunction with an increasingly skilled workforce are all having monumental shifts in how
the maritime industry is approaching new challenges and opportunities.

IoE and Blockchain: IoE helps in Automotive power infrastructure in manufacturing and for
energy production. ln the traditional method, during the time of construction, the electric
power system uses the central architecture, and this poses a number of obstacles to the
industry. Here IoE comes into the frame. lt helps to recognize some of the challenges and
accordingly proposes the best efficiency and optimal design to build an energy system.
Technology trends in the energy industry refer to automate the power infrastructure to
reduce insufficiency, make the transmission of energy more productive, reduce the expenses
and decrease the wastage of energy.
Blockchain technology combines all energy stakeholders under a single system.
Blockchains or distributed ledgers are emerging technology trends in the energy industry that
have drawn significant interest from energy supply firms, start-ups, financial institutions,
governments, technology developers and the academic community'. Block chain technology
proposes to combine all energy stakeholders under a single decentralized system. Electricity
producers, metering operators, distribution network operators and traders potentially
benefit from utilizing smart contracts. These agreements ensure that all energy-related
transactions are routed through a safe and immutable network, reducing the risk of losses.
Block chain also can achieve some degree of equity between energy generators and
consumers.

Gross Domestic Product (GDP)

It is a measure of the Economy of a country. It is the value of Goods and Services
produced minus the value of goods and services needed to produce them. It helps in knowing
the employment status. ln economics, it is widely accepted that technology is the key driver
of economic growth of countries, regions, and cities. Technological progress allows for the
more efficient production of more and better goods and services, which is what prosperity
depends on. The Indian Manufacturing sector currently contributes 16-17% to GDP and gives
employment to around l2% of the country's workforce. Various studies have estimated that
every job created in manufacturing has a multiplier effect in creating 2-3 jobs in the services
sector. Manufacturing, value added (% of GDP) in India was reported at 12.96 % in 2020,
according to the World Bank collection of development indicators, compiled from officially
recognized sources.
Steam Formation:
Definition of Steam: Steam can be defined as a mixture of water and air or it can also be
defined as vapors of water.

Formation of Steam (At Constant Pressure):

• Consider 1 kg of water at 00 C taken in a cylinder, on which a constant pressure p is

exerted. Point A on the temperature-enthalpy graph.
• When this water is heated its temperature rises till the boiling point is reached.
This temperature is called saturation temperature (Ts). Point B on the graph.
• Further addition of heat initiates the evaporation of water while the temperature
remains at saturated temperature until all of water is converted into steam. Point
C on the graph.
• On heating the steam further, it increases the temperature of steam above the
saturated temperature to superheated steam.

Saturation temperature (Ts): It is defined as the temperature at which the water begins to
boil at constant pressure.
Sensible heat (hf): It is the amount of heat required to raise the temperature of 1 kg of
water from 00 C to the saturation temperature (boiling point) at constant pressure. It is
also known as enthalpy of the liquid.
Latent heat of evaporation (hfg): It is the amount of heat required to evaporate 1 kg of
water at saturation temperature to 1 kg of dry steam at the same saturation temperature
at constant pressure. Also known as enthalpy of evaporation.

Enthalpy of superheat: the amount of heat required to increase the temperature of dry
steam from its saturation temperature to any desired higher temperature at constant
pressure is called enthalpy of superheat.

States of Steam: The steam as it is being generated can exist in 3 states as wet steam, dry
saturated steam, and superheated steam.
Wet Steam: It is defined as a two-phase mixture of entrained water molecules and steam
at saturation temperature.
Dry Steam (dry saturated steam): As wet steam is heated further, the water molecules in
the steam get converted into vapour. Dry steam is steam at saturation temperature
having no water molecules in it. Point C.
Superheated Steam: It is defined as steam which is heated beyond its dry state to
temperatures higher than its saturated temperature at the given pressure.
Dryness fraction of steam: A wet steam has different proportions of water molecules and
dry steam. Hence, the quality of wet steam is specified by the dryness fraction which
indicates the amount of dry steam in the given quantity of wet steam and is denoted by x.
It is defined as the ratio of mass of dry steam in each quantity of wet steam to the total
mass of wet steam.
Let mg = mass of dry steam
mf = mass of water molecules
Dryness fraction, x =
mg/(mg+mf)
• The dryness fraction of wet steam is less than 1.
• The dryness fraction of dry steam is 1.
Enthalpy (h), kJ/kg: It is the amount of heat required to raise the temperature of 1 kg of
water from 00 C to the desired form of steam at constant pressure. It is the sum of the
internal energy and work done at constant pressure.

Enthalpy of Dry Saturated Steam (hg): It is the amount of heat required to raise the
temperature of 1 kg of water from 00 C to 1 kg of dry saturated steam at constant
pressure.
= +

Enthalpy of Wet Steam (h): It is the amount of heat required to raise the temperature of
1 kg of water from 00 C to 1 kg of wet steam to the specified dryness fraction, at constant
pressure.
h= +

Enthalpy of Superheated Steam (hsup): It is the amount of heat required to raise the
temperature of 1 kg of water from 00 C to 1 kg of superheated steam to the stated
saturated steam temperature, at constant pressure. It is the sum of enthalpy of dry steam
and the amount of superheat.
= + ( + )

= + + ( + )

* Where is the specific heat of superheated steam.

Steam Properties:
The important properties of steam are.
1. Pressure
2. Temperature
3. Specific volume
4. Enthalpy
5. Internal energy
6. Entropy
Specific Volume (m3/kg): It is the volume occupied by the unit mass of a substance.
Specific Volume of Dry Saturated Steam (vg): It is the volume occupied by 1 kg of dry
saturated steam at a given pressure.
Specific Volume of Wet Steam (v): It is the volume occupied by 1 kg of wet steam to the
specified dryness fraction at a given pressure.
v=x

Internal Energy of Steam: The total heat energy of dry saturated steam at a constant
pressure is the sum of the sensible heat and latent heat. But in latent heat a portion is
used for external work. Therefore, the actual energy stored in the steam is the sensible
heat and the internal latent heat. This actual energy stored in steam is called internal
energy of steam. It is defined as the difference between the enthalpy of steam and the
external work of evaporation.

HEAT TRANSFER

The physical act of the transfer of thermal energy between two systems by the dissipation
of heat is known as heat transfer. The three modes of heat transfer are conduction,
convection, and radiation.

In our everyday life, it has been observed that when a pan full of water is boiled on a
flame, its temperature increases, but when the flame is turned off, it slowly cools down.
This is because of the phenomenon of heat transfer taking place between the pan full of
water and the flame. It has been established that heat transfer takes place from hotter
objects to colder objects. When there are objects which are at different temperatures or
there is an object at a different temperature from the surroundings, then the transfer of
heat takes place so that the object and the surroundings both reach an equilibrium
temperature.

Modes of Heat Transfer

There are primarily three modes of heat transfer.

1. Conduction

2. Convection

3. Radiation

CONDUCTION OF HEAT

Heat conduction is a process in which heat is transferred from the hotter part to the
colder part in a body without involving any actual movement of the molecules of the
body. Heat transfer takes place from one molecule to another molecule as a result of the
vibratory motion of the molecules. Heat transfer through the process of conduction
occurs in substances which are in direct contact with each other. It generally takes place
in solids.

Conduction example: When frying vegetables in a pan. Heat transfer takes place from
flame to the pan and then to the vegetables.

CONVECTION OF HEAT

In this process, heat is transferred in the liquid and gases from a region of higher
temperature to a region of lower temperature. Convection heat transfer occurs partly due
to the actual movement of molecules or due to the mass transfer.

For example. Heating of milk in a pan.

RADIATION OF HEAT

It is the process in which heat is transferred from one body to another body without
involving the molecules of the medium. Radiation heat transfer does not depend on the
medium.

For example: In a microwave, the substances are heated directly without any heating
medium.
 POWER PLANTS

1. Basic Working Principle of Hydel Power Plant

 Hydroelectric power plants, also known as hydropower plants, generate electricity by utilizing
the energy of flowing or falling water. The basic working principle of a hydropower plant
involves several key components:
Water Source: Hydropower plants are typically located near water sources such as rivers,
streams, or reservoirs. The availability and flow rate of water are crucial factors for the
plant's operation.
Dam or Diversion Structure: In large-scale hydropower plants, a dam is often constructed to
create a reservoir by impounding water. The dam controls the flow of water and regulates
its release downstream. In run-of-river hydropower plants, a diversion structure is used to
channel water from the river without the need for a dam.
Penstock: The penstock is a large pipe or conduit that carries water from the reservoir or
diversion structure to the turbine. The pressure of the water increases as it descends
through the penstock, which enhances the efficiency of the turbine.
Turbine: The turbine is the primary component where the kinetic energy of the flowing water
is converted into mechanical energy. There are various types of turbines used in
hydropower plants, including Pelton, Francis, and Kaplan turbines, each suited for different
flow conditions.
Generator: Connected to the turbine, the generator converts the mechanical energy
produced by the turbine into electrical energy. The generator typically consists of coils of
wire rotating within a magnetic field, inducing an electric current according to Faraday's law
of electromagnetic induction.
Transmission Lines: The electricity generated by the generator is transmitted through high-
voltage transmission lines to distribution networks and eventually to consumers.
Control System: A control system monitors and regulates the operation of various
components of the hydropower plant, including the flow of water, the speed of the turbine,
and the output of electricity. This ensures optimal performance and safety.
Overall, the basic principle involves harnessing the energy of flowing water to rotate a turbine,
which drives a generator to produce electricity. Hydropower plants are considered a
renewable and sustainable source of energy, as they rely on the natural water cycle and do
not produce greenhouse gas emissions during operation.

2. Basic Working Principle of Steam Power Plant

A steam power plant, also known as a thermal power plant, generates electricity by
converting thermal energy from burning fossil fuels or nuclear reactions into mechanical
energy and then into electrical energy. The basic working principle of a steam power plant
involves several key components:
Boiler: The boiler is where fuel, such as coal, natural gas, or oil, is burned to produce high-
pressure steam. In nuclear power plants, nuclear reactions generate the heat needed to
produce steam. The heat produced in the boiler turns water into steam at high
temperatures and pressures.
Steam Turbine: The high-pressure steam generated in the boiler is directed into a steam
turbine. The steam's high pressure and temperature cause the turbine blades to rotate.
Generator: Connected to the steam turbine, the generator converts the mechanical energy
produced by the turbine into electrical energy. The generator typically consists of coils of
wire rotating within a magnetic field, inducing an electric current according to Faraday's law
of electromagnetic induction.
Condenser: After passing through the turbine, the steam is condensed back into water in
the condenser. This is typically achieved by passing the steam through a series of tubes
cooled by water from a nearby water source, such as a river or cooling tower. Condensing
the steam back into water reduces its volume, allowing for more efficient operation of the
turbine.
Cooling System: The cooling system, which may include cooling towers, ponds, or rivers, is
responsible for dissipating the waste heat generated during the condensation process. This
helps maintain the efficiency of the power plant and prevents overheating of equipment.
Feedwater Pump: The condensed water from the condenser is pumped back into the boiler
to be heated again and converted into steam. The feedwater pump ensures a continuous
supply of water to the boiler.
Control System: A control system monitors and regulates the operation of various
components of the steam power plant, including the fuel input, steam temperature and
pressure, turbine speed, and electrical output. This ensures optimal performance and safety.
Overall, the basic principle involves using heat energy to produce steam, which drives a
turbine connected to a generator to produce electricity. Steam power plants are commonly
used for electricity generation due to their high efficiency and reliability, although concerns
about environmental impact and greenhouse gas emissions have led to increasing interest in
renewable energy sources.

3. Basic Working Principle of Nuclear Power Plant

A nuclear power plant generates electricity by utilizing the heat produced from nuclear
reactions to produce steam, which then drives a turbine connected to a generator. The basic
working principle of a nuclear power plant involves several key components:
Nuclear Reactor: The heart of a nuclear power plant is the nuclear reactor, where nuclear
fission reactions occur. In a nuclear reactor, uranium or plutonium nuclei are bombarded by
neutrons, causing them to split into smaller nuclei and release a large amount of heat
energy. This process is known as nuclear fission.
Fuel Rods: The nuclear fuel, typically enriched uranium or plutonium is formed into ceramic
pellets and sealed inside metal tubes called fuel rods. These fuel rods are arranged in
bundles within the reactor core.
Control Rods: Control rods made of materials such as boron or cadmium are inserted into
the reactor core to regulate the rate of the nuclear fission reactions. By absorbing neutrons,
control rods can slow down or stop the chain reaction, allowing operators to control the
reactor's power output.
Coolant: A coolant, such as water, heavy water, or liquid sodium, circulates through the
reactor core to transfer heat away from the fuel rods. The heated coolant absorbs the heat
generated by nuclear fission reactions and carries it to a heat exchanger.
Heat Exchanger: The heat exchanger transfers the thermal energy from the coolant to a
separate water loop, converting it into high-pressure steam. The coolant remains contained
within a closed loop and does not come into direct contact with the water used to produce
steam for electricity generation.
Steam Turbine: The high-pressure steam produced in the heat exchanger is directed into a
steam turbine. The steam's high pressure and temperature cause the turbine blades to
rotate.
Generator: Connected to the steam turbine, the generator converts the mechanical energy
produced by the turbine into electrical energy. The generator typically consists of coils of
wire rotating within a magnetic field, inducing an electric current according to Faraday's law
of electromagnetic induction.
Condenser: After passing through the turbine, the steam is condensed back into water in
the condenser. This is typically achieved by passing the steam through a series of tubes
cooled by water from a nearby water source, such as a river or cooling tower.
Cooling System: The cooling system, like that used in conventional steam power plants,
dissipates the waste heat generated during the condensation process.
Control System: A control system monitors and regulates the operation of various
components of the nuclear power plant, including reactor power level, coolant flow rate,
steam pressure, turbine speed, and electrical output. This ensures optimal performance and
safety.
Overall, the basic principle involves harnessing the heat energy from nuclear reactions to
produce steam, which drives a turbine connected to a generator to produce electricity.
Nuclear power plants provide a significant portion of the world's electricity, offering a low-
carbon alternative to fossil fuel-based power generation. However, safety concerns and the
management of nuclear waste remain significant challenges for the nuclear power industry.
4. Basic Working Principle of Tidal Power Plant

A tidal power plant generates electricity by harnessing the energy of tides, which are caused
by the gravitational forces of the moon and the sun acting on the Earth's oceans. The basic
working principle of a tidal power plant involves several key components:
Tidal Basin or Barrage: A tidal power plant typically consists of a structure, such as a barrage
or dam, built across an estuary or bay. This structure creates a tidal basin, where the water
level rises and falls with the incoming and outgoing tides.
Tidal Turbines: Within the tidal basin, underwater turbines are installed to capture the
kinetic energy of the moving water. These turbines resemble underwater wind turbines and
are designed to operate efficiently in the changing flow of tidal currents.
Tidal Currents: As the tide rises and falls, water flows in and out of the tidal basin through
the turbines. The flow of water drives the turbines, causing them to rotate and generate
mechanical energy.
Generator: Connected to the tidal turbines, the generator converts the mechanical energy
produced by the turbines into electrical energy. The generator typically consists of coils of
wire rotating within a magnetic field, inducing an electric current according to Faraday's law
of electromagnetic induction.
Transmission Lines: The electricity generated by the generator is transmitted through
underwater cables to onshore substations and integrated into the electrical grid for
distribution to consumers.
Control System: A control system monitors and regulates the operation of various
components of the tidal power plant, including the positioning of the turbines, the flow of
tidal currents, and the output of electricity. This ensures optimal performance and safety.
The basic principle involves using the movement of tidal currents to drive underwater
turbines, which in turn generate electricity. Tidal power plants are considered a renewable
energy source because tides are predictable and occur regularly due to the gravitational pull
of the moon and the sun. However, tidal power plants are typically location-specific and
require suitable tidal ranges and currents to be economically viable. Additionally,
environmental impacts such as habitat disruption and changes in sediment transport must be
carefully considered when planning and operating tidal power projects.
5. Basic Working Principle of wind Power Plant

A wind power plant, also known as a wind farm, generates electricity by harnessing the
kinetic energy of wind and converting it into mechanical energy and then electrical energy.
The basic working principle of a wind power plant involves several key components:
Wind Turbines: The primary component of a wind power plant is the wind turbine. Wind
turbines consist of rotor blades mounted on a hub, which is connected to a shaft. The blades
capture the kinetic energy of the wind and start to rotate.
Gearbox and Generator: As the blades rotate, they turn the shaft, which is connected to a
gearbox. The gearbox increases the rotational speed of the shaft to drive a generator. The
generator converts the mechanical energy from the rotating shaft into electrical energy.
Transformer: The electricity generated by the generator is typically in the form of
alternating current (AC) with a relatively low voltage. This electricity is passed through a
transformer to increase its voltage to a level suitable for transmission over long distances.
Power Grid Connection: The electricity from the wind power plant is then fed into the power
grid through transmission lines. It is integrated with electricity from other sources and
distributed to consumers.
Control System: A control system monitors and regulates the operation of the wind
turbines, adjusting the blade pitch and yaw angle to optimize performance based on wind
speed and direction. The control system also ensures the safety and efficiency of the wind
power plant.
The basic principle involves using the kinetic energy of wind to rotate the blades of wind
turbines, which in turn drives generators to produce electricity. Wind power plants are
considered a renewable energy source because wind is abundant and naturally replenished.
They provide clean energy without emitting greenhouse gases or other pollutants associated
with fossil fuel combustion. However, the availability and consistency of wind vary depending
on location and weather conditions, so wind power plants are often complemented by other
forms of energy generation in power systems.