UNIT–III

Power plants – Working principle of Steam, Diesel, Hydro, Nuclear power plants.
Mechanical Power Transmission - Belt Drives, Chain, Rope drives, Gear Drives and their
applications.
Introduction to Robotics - Joints & links, configurations, and applications of robotics.

Working Principle of Thermal Power Plant or Working

Principle of Thermal Power Plant
Thermal power plant” as the title infers is the mechanism which converts heat energy into
electric power.
Thermal power plants, convert heat energy into electricity. They are the backbone of global
electricity generation, providing around 60% of the world’s power.

Boiler: The boiler heats water to produce steam.

Turbine: The turbine expands the steam to produce mechanical energy
Generator: The generator converts the mechanical energy from the turbine into
electrical energy.
Condenser: The condenser cools and condenses the steam back into water.
Cooling tower: The cooling tower transfers heat from the condenser to the
atmosphere.

Working principle of steam power plant :

 A steam power plant using steam as working substance works basically cycle.
 Coal received in coal storage yard of power station, is transferred in the furnace
by coal handling unit.
 Heat produced due to burning of coal is utilized in converting water contained
in boiler drum into steam at suitable pressure and temperature.
 The steam generated is passed through the super heater.
 Superheated steam then flows through the turbine.
 After doing work in the turbine the pressure of the steam is reduced.
 Steam leaving the turbine passes through the condenser which maintain the low
pressure of steam at the exhaust of turbine.
 Steam pressure in the condenser depends upon flow rate and temperature of the
cooling water and on effectiveness of air removal equipment water circulating
through the condenser may be taken from the various sources, such as- river,
take or sea.
Advantages And Disadvantages Of A Thermal Power Plant
Advantages:
 Less initial cost as compared to other generating stations.
 It requires less land as compared to hydro power plant.
 The fuel (i.e. coal) is cheaper.
 The cost of generation is lesser than that of diesel power plants.
Disadvantages:
 It pollutes the atmosphere due to the production of large amount of smoke.
This is one of the causes of global warming.
 The overall efficiency of a thermal power station is low (less than 30%)

Or
 Working Principle of Diesel Power Plant
Applications of Diesel Electric Station:
1.Locomotives 2. Standby Plant 3. Peak Load Plant 4. Emergency Plant
5. Mobile Plant 6. Nursery Plant 7. Supply Units for Cinemas, Hospitals etc
Principle of Diesel Power Plant
 The working principle of a diesel generator is established on the
thermodynamics law of energy conversion.
 To produce AC (alternating current) power, diesel generators go through a
series of stages. When the diesel generator starts,
 its four combustion processes: suction, compression, power, and exhaust.
As a consequence, the fuel’s chemical energy is transformed into rotational
mechanical energy.
 This mechanical energy is employed to turn a crankshaft. The spinning
shaft is now used to rotate the alternator’s rotor.
 The rotor and stator are the two crucial parts of an alternator that creates
electricity.
 The rotor, a cylindrical component surrounded by magnets, spins inside
the stator, which is made up of a fixed arrangement of conductive copper
wiring.
 Electricity is generated when the rotor spins. The magnets surrounding the
rotor are precisely positioned to create a magnetic field as they pass through
the stator’s copper wiring. The magnetic field is commonly produced by two
polarized magnets in an electric generator application. This magnetic field
generates voltage, which is captured by the stator. The voltage regulator then
delivers the electricity to the desired location .
 The alternator produces an AC, which is converted to DC with the help of
a rectifier in a diesel generator.
The advantages of diesel power plants:
1. The layout of the diesel power plant is quite simple.
2. The limited quantity of cooling water required.
3. Low fuel cost for operation.
4. Smaller storage is needed for the fuel.
5. There is no problem of ash handling..
6. For small capacity power generation, diesel power plant is more
efficient than the steam power plant.
7. Quickly started and put on load.
8. They can respond to varying loads without having any difficulty.
Disadvantages:
The disadvantages of diesel power plants are listed below:
1. High Maintenance and operating cost.
2. The plant cost per kW power is comparatively more.
3. The plant produces too much noise.
Working Principle of Hydro Power Plants.

Hydro Power Plant Working:

In a large amount of water is available or you can say a river. The water is
being stored in the reservoir which is in the form of potential energy. With the
use of the control gate, the water is being released and water starts flowing
into the penstock. Here two components are attached 1. Surge tank, Valve,
and Nozzle.
Initially, the valve is closed. But when the water reaches up to the max level
that can create high pressure then we on the valves. The water with high
pressure starts flowing and strikes to the turbine blades through the nozzle.

The turbine blades start rotating. So till now, we observed the water which is
having PE is now converting into KE.

In the turbine blade, an electric motor is attached to the turbine shafts. So

rotation of turbine blades also rotates the turbine shafts, which also rotates the
electric motor. Hence Kinematic energy into mechanical energy and then
further it is converted into electric energy.

The energy generated is sent to the powerhouse, Transformer, and

Transmission line.
The water which is rotating the turbine blades is now sent to the river via a
tailrace.

The hydropower plant is constructed to store the water in a large amount.

When the water reaches up to the max level then it is being released which
also causes the flood in some area (due to sudden release of water).

Hydro Power Plant Advantages:.

 These are simple in design easy to maintain, pollution-free with zero
fuelling cost.
 The cost of power generation is less.
 The life expectancy of a hydroelectric power plant is more..
 There is no problem with handling the fuel and ash and no nuisance of
smoke
 The fuel needed for the thermal plant has to be purchased, whereas in
Hydro-plant the fuel cost is totally absent.
 Hydroelectric plants are quick to respond to the change of load compared
with thermal Power Plant or nuclear plants.
Hydro Power Plant Disadvantages:
 The capital cost of the hydro plant is considerably more than the thermal
plant.
 It takes a considerable long time for its erection compared with thermal
plants.
 Power generation by the hydro plant is only dependent on the quantity of
water
 The transmission of power from the power station to the load center
requires along transmission lines..
WORKING PRINCIPLE OF NUCLEAR POWER PLANTS.
COMPONENTS OF NUCLEAR POWER PLANT :
Nuclear Fuel :Normally used nuclear fuel is uranium (U235)
Fuel Rods: The fuel rods hold nuclear fuel in a nuclear power plant.

Neutron Source: A source of neutron is required to initiate the fission for the
first time. A mixture of beryllium with plutonium is commonly used as a
source of neutron.
Reactor:
• Nuclear fission takes place in the reactor only.
• Nuclear fission produces large quantity of heat.
• The heat generated in the reactor is carried by coolant circulated through
the reactor.
Control Rods:
• They are used to control the chain reaction.
• They are absorbers of neutrons.
• The commonly used control rods are made up of cadmium or boron.
Moderator:
• Moderators are used to slow down the fast neutrons.
Fuel Rods:
• The fuel rods hold nuclear fuel in a nuclear power plant.
Neutron Reflectors:
• To prevent the leakage of neutrons to large extent.
• In PHWR, the moderator itself acts as reflectors.
Shielding:
To protect from harmful radiations the reactor is surrounded b a concrete wall
of thickness about 2 to 2.5 m.
WORKING PRINCIPLE OF NUCLEAR POWER PLANT:
• The heat generated in the reactor due to the fission of the fuel is taken up
by the coolant.
• The hot coolant then leaves the reactor and flows through the steam
Generator.
• In the steam generator the hot coolant transfers its heat to the feed water
which gets converted into steam.
• The steam produced is passed through the turbine, which is coupled with
generator.
• Hence the power is produced during the running of turbine.
• The exhaust steam from the turbine is condensed in the condenser.
• The condensate then flows to the steam generator through the feed pump.
• The cycle is thus repeated.
Advantages of Nuclear Power Plant:
• Requires less space compared to steam power plant.
• Fuel transport cost is less..
• Water required is very less.
Disadvantages of Nuclear Power Plant:
• Initial Cost is higher.
• Not suitable for varying load condition.
• Radioactive wastes are hazardous.
• Maintenance cost is higher.
• Trained workers are required to operate the plant.

Nuclear Power Plants in India:

• IGCAR, Kalpakkam in Chennai. • Rana Pratap Sagar in Rajasthan
• Narora in Uttar Pradesh • Kakarpur near Surat at Gujarat

Mechanical Power Transmission

Belt Drives, Chain, Rope Drives, Gear Drives & Their Applications.

 The power is transmitted from one shaft to the other by means of belts,
chains and gears.
 The belts and ropes are flexible members which are used where distance
between the two shafts is large. High speed Low torque
 The chains also have flexibility but they are preferred for intermediate
distances. Low speed High torque
 The gears are used when the shafts are very close with each other.
High speed High torque
.

What is Belt Drive?

 The belt drive is connected to two systems:
 The driver system and the driven system.
 The driver system is connected to the power source is called a driving system and
the driven system to which rotation is transmitted is called a driven system.

Open Belt Drive:

The open belt drive, as shown in Figure below, is used with shafts arranged
parallel and rotating in the same direction. In this case, the driver A pulls the belt
from one side (i.e. lower side RQ) and delivers it to the other side (i.e. upper side
LM). Thus, the tension in the lower side belt will be more than that in the upper side
belt. The lower side belt (because of more tension) is known as tight side whereas
the upper side belt (because of less tension) is known as slack side, as shown in Fig.

Crossed belt drive. The crossed belt drive, as shown in Figure below, is used
with shafts arranged parallel and rotating in the opposite directions. In this case, the
driver pulls the belt from one side (i.e. RQ) and delivers it to the other side (i.e.
LM). Thus, the tension in the belt RQ will be more than that in the belt LM. The
belt RQ (because of more tension) is known as tight side, whereas the belt LM
(because of less tension) is known as slack side, as shown in Figure below.

Advantages of Belt drive:

1. Belt drive has Greater reliability.
2. Less noise compared to chain drives.
3. No oiling or greasing is required.
4. Belt drives are more flexible and easy to replace.
Disadvantages of Belt drive:
 The main disadvantage of belt drives is that they are susceptible to
contamination by dirt, lubricants, oil, water, etc., which can cause
problems with operation.
 Life span is less compared to shaft and gearbox system.
Application Of Belt Drive:-
 In washing machines
 Flour mills.
 Lathe Machine, Milling Machines, Drilling machine, etc
 Paper mills
Advantages of Gear drive:
 It is positive drive hence velocity remains constant
 It can be used even for low speeds
 It can transmit high torque values
 It is compact in construction
Disadvantages of Gear drive:
 They are not suitable when shafts are distant
 At high speeds noise and vibration happens
 It requires lubrication
 It has no flexibility
Rope Drive:-The rope drive is widely used where a large amount of power is
to be transmitted, from one pulley to another, over a considerable
distance. Rope drives use a number of circular section ropes, rather than a
single flat or vee belt.
Types of Ropes:The rope drive uses the following two types of ropes:
1. Fibre Ropes
2. Wire ropes.
Fibre Ropes:The ropes for transmitting power are usually made from fibrous,
materials such as hemp, manila and cotton. Since the hemp and manila fibres
are rough, Therefore the ropes made from these fibres are not very flexible
and possesses poor mechanical properties.

Wire Ropes:-
 When a large amount of power is to be transmitted over long distances
from one pulley to another, then wire ropes are used.
 The wire ropes are widely used in elevators, mine hoists, cranes,
conveyors, hauling devices and suspension bridges.
 The wise ropes run on grooved pulleys but they rest on the bottom of the
grooves and are not wedged between the sides of the grooves.
Advantages:
 Wire ropes are lighter in weight,
 These can withstand shock loads.
 Wire ropes are more reliable,
 Less expensive or low in cost.
APPLICATIONS:
Elevators, Mine hoists , Cranes , Conveyors , Suspension bridges.
Lifting and hoisting in cranes and elevators.
 INTRODUCTION TO ROBOTICS:-
Robotics is a branch of engineering and science that includes electronics
engineering, mechanical engineering and computer science and so on. This
branch deals with the design, construction, use to control robots, sensory
feedback and information processing. These are some technologies which
will replace humans and human activities in coming years.
ROBOT:-A Robot is a programmable,multifunctional manipulator designed
to move matierials, parts,tools,through programmed for varieties of tasks.
TYPES OF ROBOTS:
I. TYPE OF CONTROL.
 Point to point robot.
 Contineoous robot.
II. CAPABULITY.
 Sequance robot.
 Intelligent robot.
III. CONFIGURATION.
 Cartesian.
 Cylindrical.
 Spherical.

ROBOT JOINTS:-
Robotic joints, which are sometimes known as axes, are the moveable parts of
a robot that cause relative motion between adjacent links. These links refer to the
rigid components that connect the joints to ensure their proper and straightforward
operation.
TYPES:-
1. Linear joint.
2. Orthogonal joint.
3. Rotational joint.
4. Twisting joint.
5. Revolving joint.
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 QUESTION BANK
1. Explain the working principle of nuclear power plant with neat sketch
2. Explain the working principle of hydroelectric power plant with neat sketch
3. Draw a schematic lay out of thermal plant
4. Draw the general layout of steam power plant and explain its major components.
5. Examine the construction and working of Nuclear power plant with a layout.
6. Express the advantages and disadvantages of a diesel power plant over a gas
turbine power plant.
7. Explain the classification of gears with neat sketches
8. Discuss about the various types of belt drives with neat sketches?
9. State the advantages and disadvantages of the chain drive over belt and rope
drive.
10. Mention four important types of gears and discuss their applications and
their materials used. Advantages and disadvantages of Gears?
11. Define a robot. Name the commonly used robot configurations. Explain
cylindrical. Configuration robot.
12. Define a robot. Name the commonly used robot configurations. Explain polar
configuration robot.
13. Define a robot. Name the commonly used robot configurations. Explain
cartesian.configuration robot.
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14. Define Robot Joint? Give classification and explain them with neat sketch
Assignment questions
SET No-I
1. Explain the working principle of nuclear power plant with neat sketch
2. Explain and Express the advantages and disadvantages of a diesel power plant .
3. Explain the classification of gears with neat sketches
4. Define a robot. Name the commonly used robot configurations. Explain
cylindrical. Configuration robot.
5. Define Robot Joint? Give classification and explain them with neat sketch

SET No-II
1. Explain the working principle of hydroelectric power plant with neat sketch
2. Draw the general layout of steam power plant and explain its major components
3. Discuss about the various types of belt drives with neat sketches? Write the
differences between Open belt drive &cross belt Drive.
4. Define a robot. Name the commonly used robot configurations. Explain polar
configuration robot.
5. Define Robot Joint? Give classification and explain them with neat sketch

SET No-III
1. Explain the working principle and draw a schematic lay out of thermal
plant
2. Explain the working principle of nuclear power plant with neat sketch
3. Mention four important types of gears and discuss their applications and
their materials used. Advantages and disadvantages of Gears?
4. Define a robot. Name the commonly used robot configurations. Explain
Cartesian configuration robot.
5. Define Robot Joint? Give classification and explain them with neat
sketch

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