Mechanical Engineering

UPSC Mechanical Engineering 2022

All 16 questions from the 2022 Civil Services Mains Mechanical Engineering paper across 2 papers — 800 marks in total. Each question comes with a detailed evaluation rubric, directive word analysis, and model answer points.

16Questions
800Total marks
2Papers
2022Exam year

Paper I

8 questions · 400 marks
Q1
50M Compulsory solve Mechanisms, stress analysis, materials and gears

(a) A slider-crank mechanism with crank radius 60 mm and connecting rod length 240 mm is shown in Figure 1(a). The crank is rotating with a uniform angular speed of 10 rad/s, counterclockwise. For the given configuration, determine the speed of the slider. A and B in Figure 1(a) are at the same horizontal level. (10 marks) (b) In a complex two-dimensional stress system, the maximum and minimum principal stresses are found to be 160 MPa tensile and 80 MPa compressive. The material elastic limit is 300 MPa in a simple tension test. Find factor of safety using the following theories: (i) Maximum principal stress theory (ii) Maximum shear stress theory (iii) Maximum distortion energy theory (10 marks) (c) A pipe with external forces is shown in Figure 1(c). The loads 300 N, 200 N, and 900 N are acting at the centres of pipe sections as shown in the figure. Find the resultant of force system at point A shown in the figure. (10 marks) (d) Compare thermosetting and thermoplastic types of plastics in terms of properties, response to heating and applications. (10 marks) (e) Two meshing spur gears with pressure angle of the involute teeth being 20° have addendum equal to one module. The pinion has 14 teeth and the larger gear has 54 teeth. Does the interference occur? If it occurs, what should be the change in the pressure angle in order to eliminate interference? Take standard module = 10 mm. (10 marks)

Answer approach & key points

Solve each sub-part systematically: for (a) apply velocity polygon or analytical method for slider-crank; for (b) compute factor of safety using all three failure theories with proper stress transformations; for (c) resolve forces and moments about point A; for (d) construct a comparative table of thermosetting vs thermoplastic polymers; for (e) check interference using minimum teeth and contact ratio criteria, then recalculate pressure angle if needed. Allocate approximately 15% time to (a), 20% to (b), 15% to (c), 20% to (d), and 30% to (e) due to its analytical complexity.

  • (a) Slider speed using velocity analysis: v_B = ω × r = 10 × 0.06 = 0.6 m/s tangential; velocity polygon or analytical solution gives slider velocity ≈ 0.5196 m/s or 0.52 m/s (using n = l/r = 4, θ = 90°)
  • (b)(i) Maximum principal stress theory: σ1 = 160 MPa < 300 MPa, FOS = 300/160 = 1.875
  • (b)(ii) Maximum shear stress theory: τ_max = (160-(-80))/2 = 120 MPa, allowable τ = 300/2 = 150 MPa, FOS = 150/120 = 1.25
  • (b)(iii) Maximum distortion energy theory: σ_eq = √(160² + (-80)² - 160×(-80)) = √44800 ≈ 211.66 MPa, FOS = 300/211.66 ≈ 1.417
  • (c) Resultant force and moment at A: resolve 300N, 200N, 900N into components; calculate resultant force vector and resultant moment about A
  • (d) Comparison table: thermoplastics (PE, PP, PVC) - linear chains, reversible softening, recyclable, lower strength; thermosets (Bakelite, epoxy) - cross-linked, irreversible curing, higher heat resistance, used in composites and electrical fittings
  • (e) Interference check: minimum teeth for 20° full depth = 18 (pinion has 14 < 18), interference occurs; new pressure angle φ' where cos φ' = (t_p/2)sin²φ/(1+2/t_g) or using limiting condition, φ' ≈ 23.5° to 25° range
Q2
50M calculate Shaft stress analysis, crystal structures and engine dynamics

(a) A 20 mm diameter shaft is subjected to a torque of 80 Nm and a downward bending moment of 100 Nm at the centre. Draw the state of stress on the bottom surface of the shaft at the centre and find principal stresses and shear stress at the centre of the bottom surface. What is the angle of shear plane? (15 marks) (b) What is Atomic Packing Factor of a crystal structure? Calculate the atomic packing factor of aluminium assuming atoms to be of spherical shape with atomic radius 'R'. (15 marks) (c) The cranks of a three-cylinder single acting engine are set equally at 120°. The engine speed is 540 rpm. The turning moment diagram for each cylinder is a triangle for the power stroke with a maximum torque of 100 Nm at 60° after dead-centre of the corresponding crank. On the return stroke, the torque is sensibly zero. Determine the: (i) power developed by the engine (ii) coefficient of fluctuation of speed if the flywheel has a mass of 7·5 kg with a radius of gyration of 65 mm (iii) coefficient of fluctuation of energy (iv) maximum angular acceleration of the flywheel (20 marks)

Answer approach & key points

Calculate the principal stresses and shear plane angle for part (a) using combined bending-torsion theory; define and derive APF for FCC aluminium in part (b); solve the engine dynamics problem in part (c) by superposing three triangular turning moment diagrams, finding mean torque, then computing power, fluctuation coefficients and angular acceleration. Allocate approximately 30% time to (a), 25% to (b), and 45% to (c) due to its four sub-parts and higher marks.

  • Part (a): Bending stress σ = 32M/(πd³) = 318.3 MPa; Torsional shear stress τ = 16T/(πd³) = 127.3 MPa; principal stresses σ₁,₂ = (σ/2) ± √[(σ/2)² + τ²] = 364.7 MPa and -46.4 MPa; maximum shear stress τ_max = 205.6 MPa; shear plane angle θ_s = ½ tan⁻¹(2τ/σ) = 19.3°
  • Part (b): Definition of APF as ratio of volume occupied by atoms to total unit cell volume; aluminium is FCC with 4 atoms per unit cell; lattice parameter a = 2√2 R; APF = [4 × (4/3)πR³] / a³ = 0.74 or 74%
  • Part (c)(i): Power = 3 × (area under one TM diagram) × (ω/2π) = 3 × (½ × π × 100) × (540×2π/60) / (2π) = 8.48 kW or using mean torque method
  • Part (c)(ii): Coefficient of fluctuation of speed C_s = Δω/ω_mean derived from energy fluctuation ΔE = ½I(ω₁² - ω₂²); with I = mk² = 7.5 × (0.065)² = 0.0317 kg.m²
  • Part (c)(iii): Coefficient of fluctuation of energy C_E = (E_max - E_min)/work done per cycle = ΔE/(P × 60/N); determined from turning moment diagram energy integration
  • Part (c)(iv): Maximum angular acceleration α_max = (T_max - T_mean)/I occurring at instant of maximum excess torque; requires locating where combined TM is farthest from mean
  • Part (c) superposition: Combined TM diagram constructed by adding three 120°-phased triangular diagrams; mean torque line identified; energy fluctuations calculated by integrating areas above and below mean
Q3
50M calculate Thin cylinder, beam SFD/BMD, governor

(a) A thin cylinder of diameter 200 mm and length 1000 mm is subjected to an internal pressure of 10 MPa. The allowable stress of the material is 200 MPa and Young's modulus is 200 GPa. Determine the thickness, hoop and longitudinal strains under the given pressure. (10 marks) (b) A beam carries a uniformly distributed load of 360 N/m over the entire span together with a concentrated load of 400 N at the extreme left. The beam is having a span of 10 m and is supported at two points 7 m apart. The supports are so chosen, that each support carries half the total load. Draw the shear force and bending moment diagrams after obtaining the maximum bending moment and points of contraflexure. (20 marks) (c) In a Hartnell governor, the lengths of ball and roller arms of the bell crank lever are 100 mm and 80 mm respectively. Each ball has a mass of 1·5 kg. The extreme radii of rotation of the balls are 90 mm and 140 mm. The minimum equilibrium speed is 840 rpm and the maximum equilibrium speed is 5% greater than this. Assuming the sleeve to be of negligible mass and neglecting friction and obliquity of arms, determine: (i) Spring stiffness (ii) Initial compression of the central spring (iii) Equilibrium speed corresponding to radius of rotation of 130 mm (20 marks)

Answer approach & key points

Calculate the required quantities for each sub-part systematically: for (a) apply thin cylinder stress formulas and strain relations; for (b) first determine support positions using moment equilibrium about supports condition, then draw SFD/BMD with contraflexure points; for (c) apply Hartnell governor equilibrium equations at minimum and maximum speeds. Allocate approximately 20% time to part (a), 40% to part (b) due to complex loading and diagram construction, and 40% to part (c) with its three sub-requirements. Present derivations stepwise with clear free-body diagrams for the beam and governor lever systems.

  • Part (a): Thickness t = pD/(2σ_allow) = 10×200/(2×200) = 5 mm; hoop strain ε_h = (pD/4tE)(2-ν) with ν=0.3 assumed or stated; longitudinal strain ε_l = (pD/4tE)(1-2ν)
  • Part (b): Support positions determined from ΣM=0 condition that each carries half total load (2300 N each); reactions found, SFD drawn with linear and constant segments, BMD parabolic with maximum value and location identified
  • Part (b): Points of contraflexure found where BM=0, typically two points for this overhang configuration with interior supports
  • Part (c): Spring stiffness k determined from equilibrium at r₁=90mm (N₁=840 rpm) and r₂=140mm (N₂=882 rpm) using moment balance about pivot
  • Part (c): Initial compression x₀ from minimum speed equilibrium: mg + (k x₀)(b/a) = mω₁²r₁
  • Part (c): Equilibrium speed at r=130mm found by interpolating or solving governor equation with known k and x₀
  • All parts: Proper units (mm, MPa, GPa, N, m, rad/s, N/m) and significant figures maintained
Q4
50M calculate Automobile braking, annealing, balancing of rotating masses

(a) An automobile weighing 15 kN is moving at a speed of 100 km per hour. The dynamic coefficient of friction between the rubber tyre and concrete road is 0·60. When the driver jams on his brakes, the car goes into skid in the direction of motion. What is the distance the car will move before it comes to rest when (i) the road is flat, (ii) the road is 7° upward inclination, (iii) the road is 7° downward inclination? (15 marks) (b) Explain the principle of annealing with the help of Continuous Cooling Transformation (CCT) diagram. Write the purpose and applications of annealing heat treatment. (15 marks) (c) A shaft carries four masses A, B, C and D which are in complete balance. Masses C and D make angles of 90° and 210° respectively with that of mass B in the counterclockwise direction. The rotating masses A, B, C and D can be assumed to be concentrated at radii of 360 mm, 480 mm, 240 mm and 300 mm respectively. The masses B, C and D are 15 kg, 25 kg and 20 kg respectively and the planes containing B and C are 300 mm apart. Determine the following: (i) Mass A and its angular position (ii) Positions of planes A and D (20 marks)

Answer approach & key points

Calculate the braking distances for all three inclinations in part (a) using work-energy principle with friction and gravity components. For part (b), explain annealing using CCT diagram with proper time-temperature axes and transformation curves, then enumerate purposes and applications. For part (c), solve the balancing problem using vector polygon method and tabular method for planes, allocating approximately 35% time to (a), 25% to (b), and 40% to (c) given the computational complexity of the four-mass balancing problem.

  • Part (a)(i): Flat road - s = v²/(2μg) = (27.78 m/s)²/(2×0.6×9.81) = 65.6 m using work-energy principle
  • Part (a)(ii)-(iii): Inclined roads - include mg sinθ term; uphill s = v²/[2g(μcosθ + sinθ)] = 47.2 m, downhill s = v²/[2g(μcosθ - sinθ)] = 109.5 m
  • Part (b): CCT diagram with time (log scale) vs temperature axes, showing ferrite, pearlite, bainite start/finish curves; slower cooling than TTT, transformation during continuous cooling
  • Part (b): Annealing purposes - relieve internal stresses, soften for machining, improve ductility, refine grain structure; applications - cold-worked steel sheets, castings, welded components
  • Part (c): Vector polygon closure for mass moments: Σmr cosθ = 0, Σmr sinθ = 0; solve for m_A = 10 kg at 143° from B (or 217° counterclockwise)
  • Part (c): Couple polygon for planes: ΣmrL cosθ = 0, ΣmrL sinθ = 0 with reference plane; find L_A = 510 mm from reference, L_D = 255 mm from reference on opposite side of B-C
Q5
50M Compulsory solve Manufacturing and Industrial Engineering

(a) An HSS drill during its life can drill 150 through holes in a 10 mm thick brass plate at a drill speed of 400 rpm. Another drill of same type can make only 75 holes when the drill speed is increased to 600 rpm. How many holes will be produced by another drill of same type if its speed is raised to 800 rpm ? Take the feed in all the cases as same. (10 marks) (b) Write the functions of coating on Shielded Metal Arc Welding (SMAW) electrode. (10 marks) (c) Discuss the Expansionist strategy and Wait-and-See strategy for capacity timing and sizing concerning the capacity planning. (10 marks) (d) A product is to be processed from its raw form to finished form through a number of workstations. The production lead time is given as 3 days. The daily demand requirement is 500 units. Safety stock is required for one day. Container's capacity is 400 units. Determine the number of Kanbans (containers) required. (10 marks) (e) Derive the expression for Reorder point when demand is variable and lead time is constant. Suppose the average demand is 18 units per week with a standard deviation of 5 units. The lead time is constant at 2 weeks. Determine the safety stock and reorder point if management wants a 95% customer service level. (Refer Standard Normal Distribution table given on the last page) (10 marks)

Answer approach & key points

Solve each sub-part systematically: for (a) apply Taylor's tool life equation to find tool life-speed relationship and predict holes at 800 rpm; for (b) enumerate SMAW coating functions with metallurgical reasoning; for (c) compare expansionist vs wait-and-see strategies with Indian industry examples; for (d) apply Kanban formula with given parameters; for (e) derive reorder point expression using normal distribution and calculate safety stock. Allocate approximately 15% time to (a), 15% to (b), 20% to (c), 15% to (d), and 35% to (e) due to derivation requirement.

  • Part (a): Apply Taylor's equation VT^n = C; establish relationship between cutting speed and tool life; calculate holes at 800 rpm = 50 holes (or equivalent based on derived n value)
  • Part (b): List 6-8 coating functions: arc stability, gas shielding, slag formation, alloying, deoxidation, metal transfer improvement, cooling rate control, mechanical protection
  • Part (c): Define expansionist strategy (preemptive capacity ahead of demand) and wait-and-see strategy (reactive capacity after demand confirmation); compare risks, costs, and flexibility; cite Indian examples like Maruti Suzuki vs Tata Motors approaches
  • Part (d): Apply Kanban formula N = (DL(1+S))/C; with D=500, L=3, S=1/3 (safety stock 1 day vs lead time 3 days), C=400; calculate N = 5 containers
  • Part (e): Derive ROP = d̄L + zσ_d√L for variable demand, constant lead time; calculate safety stock = zσ_d√L = 1.645×5×√2 ≈ 11.62 ≈ 12 units; ROP = 36+12 = 48 units
  • Part (e) continued: Show standard normal table usage, identify z=1.645 for 95% service level, explain √L factor for demand variability over lead time
Q6
50M calculate Metal cutting, rolling and quality management

(a) During turning of a steel rod of 100 mm diameter, at a speed of 600 rpm, feed of 0·32 mm/rev and 3 mm depth of cut by a tool of the following geometry : inclination angle 0°, orthogonal rake angle – 12°, and principal cutting edge angle (φ) 60°, the following have been observed : Main cutting force component Pz = 1000 N Radial cutting force component Py = 200 N Chip thickness = 0·75 mm Using Merchant's theory, determine the force along the rake surface F, force acting perpendicular to the rake surface N, coefficient of friction between the chip-tool interface, shear force Fs and cutting power consumption. Power consumption due to feed motion may be neglected. (20 marks) (b) (i) State the sequence and purpose of different types of rolling passes, used for rolling flats and plates. (5 marks) (ii) A steel plate of 200 mm width and 30 mm thickness is rolled using two-stand rolling mill where diameter of each roller is 400 mm. Rolling is performed at 60 rev/min of roll speed to reduce thickness of steel strip from 30 mm to 26 mm. Average flow stress of metal during rolling is expressed by $$ \delta_f = \frac{K \varepsilon^n}{1+n} $$ where n = strain hardening coefficient K = strength coefficient, MPa ε = true strain Consider strength coefficient of metal (K) is 300 MPa and strain hardening coefficient (n) is 0·2 and coefficient of friction between strip and roll during rolling is 0·15. Calculate : (I) Draft in mm (II) Maximum achievable draft for above condition of rolling in mm (III) Average flow stress in MPa (IV) Rolling force in Newton (Neglect all other possibilities related to rolling) (15 marks) (c) Write the contributions of Walter A. Shewhart, W. Edwards Deming, Joseph M. Juran, Philip B. Crosby, and K. Ishikawa in the area of quality management. (10 marks)

Answer approach & key points

Calculate the required parameters for part (a) using Merchant's theory with proper force decomposition and friction analysis; for part (b) apply rolling mechanics formulas for draft, flow stress and rolling force; for part (c) enumerate quality management contributions with specific frameworks attributed to each pioneer. Allocate approximately 40% time to part (a) given its 20 marks, 30% to part (b) for 15 marks, and 20% to part (c) for 10 marks, reserving 10% for review.

  • Part (a): Calculate chip thickness ratio r = t1/t2 = 0.32/0.75 = 0.427; shear angle φ_s = arctan(r*cosα/(1-r*sinα)) = 24.6°; friction angle β = arctan((Py + Pz*tanα)/(Pz - Py*tanα)) = 22.4°; then F = Pz*sinα + Py*cosα = 2.6 N (check: actually F = sqrt(Pz²+Py²)*sin(β-α) approach); N = Pz*cosα - Py*sinα; μ = tanβ = 0.412; Fs = Pz*cosφ_s - Py*sinφ_s = 827 N; Power = Pz*V = 1000*(π*100*600/60000) = 3142 W
  • Part (b)(i): Sequence: roughing pass (break down cast structure, large reduction), intermediate/finishing pass (dimensional accuracy, surface quality); purpose of each with specific roll profiles (cambered rolls for plates, flat rolls for finishing)
  • Part (b)(ii): Draft Δh = 30-26 = 4 mm; Maximum draft Δh_max = μ²R = (0.15)²*200 = 4.5 mm; True strain ε = ln(30/26) = 0.143; Average flow stress σ̄f = 300*(0.143)^0.2/1.2 = 300*0.669/1.2 = 167.3 MPa; Contact length L = sqrt(R*Δh) = sqrt(200*4) = 28.28 mm; Rolling force F = σ̄f * L * width = 167.3*28.28*200 = 946 kN (or using 1.15 factor for plane strain: 1088 kN)
  • Part (c): Shewhart—control charts (1924), PDCA cycle foundation; Deming—14 points, system of profound knowledge, Japan's quality revolution; Juran—quality trilogy (planning-control-improvement), Pareto principle; Crosby—zero defects, 'quality is free', 14 steps; Ishikawa—cause-effect diagrams, company-wide quality control (CWQC), quality circles
  • Correct application of Merchant's circle diagram with proper force relationships and velocity relationships for part (a)
  • Recognition that maximum draft condition requires μ²R ≥ Δh for bite condition, and rolling force calculation using either Sims or simplified slab method
  • Quality management contributions linked to specific industrial outcomes (e.g., Deming's impact on Japanese automotive industry, Ishikawa's influence at Kawasaki Steel)
Q7
50M calculate Statistical quality control, facility location, welding

Q7. (a) A firm has identified four operations, which are to be conducted in succession for an order to be processed. The tolerance and mean time of each operation are given in the following table. Tolerance is independent of each other and the time is normally distributed. | Operation | Mean Time (hours) | Tolerance (hours) | |-----------|-------------------|-------------------| | 1 | 7 | 7 ± 0·6 | | 2 | 5 | 5 ± 0·6 | | 3 | 9 | 9 ± 0·8 | | 4 | 6 | 6 ± 0·3 | (i) Find the natural tolerance limits for order completion time. (20 marks) (ii) If the company sets a goal of 27·5 hours, what proportion of the orders will fail to satisfy the goal ? (iii) Find an appropriate capability index and comment. (iv) Using a technique, management has improved the operation 3 to a mean time of 8 hours. What proportion of the orders will now meet the goal ? (Use Standard Normal Distribution table given on the last page) (b) (i) Discuss the factors influencing the facility location selection. (10 marks) (ii) For expansion of a car manufacturing plant, three new locations are to be considered based on three factors : Availability of labour, Proximity to the suppliers, and Proximity to the markets. The weightage of these factors are given as 40%, 35%, and 25% respectively. The rating (on 100-point scale) of the locations against these factors are given in the following table : | Location | Availability of labour | Proximity to the suppliers | Proximity to the markets | |----------|------------------------|---------------------------|-------------------------| | X | 70 | 60 | 45 | | Y | 60 | 45 | 90 | | Z | 55 | 95 | 50 | Find the best and worst location for the new plant. (10 marks) (c) Spot welding of two steel sheets each of 1 mm thickness is performed using 20,000 A welding current supplied for 0·15 seconds. Assume that : (i) interface contact resistance is 200 micro-ohms, (ii) heat required for melting unit volume of steel is 10 J/mm³, and (iii) only 60% of heat generated is used for melting of metal at the interface. Calculate : (10 marks) (I) Heat generated, J (II) Volume of the weld nugget, mm³

Answer approach & key points

Calculate the statistical parameters for sequential operations in (a) using variance addition for independent normal distributions, then apply standard normal tables for probability calculations. For (b), apply weighted factor rating method for facility location selection. For (c), use resistance welding heat generation formula Q = I²Rt with efficiency factor. Allocate approximately 50% time to part (a) due to 20 marks and four sub-parts, 25% to part (b), and 25% to part (c).

  • Part (a)(i): Total mean = 27 hours, total variance = 0.6² + 0.6² + 0.8² + 0.3² = 1.45, σ = 1.204 hours; natural tolerance limits = 27 ± 3×1.204 = 23.388 to 30.612 hours
  • Part (a)(ii): Z = (27.5-27)/1.204 = 0.415; P(X > 27.5) = 1 - Φ(0.415) ≈ 0.339 or 33.9% orders fail
  • Part (a)(iii): Cpk = min[(USL-μ)/3σ, (μ-LSL)/3σ] with appropriate specification limits; comment on process capability
  • Part (a)(iv): New mean = 26 hours, same σ; Z = (27.5-26)/1.204 = 1.246; P(X ≤ 27.5) = Φ(1.246) ≈ 0.893 or 89.3% meet goal
  • Part (b)(i): Discuss quantitative factors (transportation cost, labour cost, utilities) and qualitative factors (community attitude, climate, political stability, environmental regulations)
  • Part (b)(ii): Weighted scores - X: 70×0.4 + 60×0.35 + 45×0.25 = 59.25; Y: 60×0.4 + 45×0.35 + 90×0.25 = 62.25; Z: 55×0.4 + 95×0.35 + 50×0.25 = 66.75; Best = Z, Worst = X
  • Part (c)(I): Heat generated Q = I²Rt = (20000)² × 200×10⁻⁶ × 0.15 = 12,000 J
  • Part (c)(II): Effective heat = 0.6 × 12000 = 7200 J; Volume = 7200/10 = 720 mm³
Q8
50M discuss Ultrasonic machining, inventory management, sourcing

Q8. (a) (i) Discuss the mechanism of material removal in ultrasonic machining. (10 marks) (ii) What are the different parameters affecting the material removal rate in ultrasonic machining ? Show the variation of material removal rate with respect to these parameters using suitable schematic. (b) (i) Discuss the ABC, VED and SDE classification of inventory items. (10 marks) (ii) A plastic moulding company provides the following details of various products in terms of annual demand and unit cost. Classify the products in A, B and C categories. (10 marks) | Item Code # | Annual Demand | Cost/Unit (₹) | |-------------|---------------|---------------| | XA-101 | 400 | 4.00 | | XA-102 | 300 | 5.00 | | XA-103 | 120 | 3.00 | | XA-104 | 80 | 2.00 | | XA-105 | 50 | 2.50 | | XA-106 | 40 | 1.50 | | XA-107 | 20 | 2.20 | | XA-108 | 15 | 32.00 | | XA-109 | 8 | 51.80 | | XA-110 | 6 | 42.00 | | XA-111 | 5 | 3.00 | (c) Discuss the various steps used in sourcing of a product or service. Also, mention the name of the factors influencing the sourcing decision. (10 marks)

Answer approach & key points

Discuss the material removal mechanism in USM with emphasis on cavitation, hammering and erosion effects; for part (b) explain ABC/VED/SDE classifications with clear criteria and perform the ABC analysis calculation showing cumulative percentage steps; for part (c) outline the sourcing process from need identification to supplier relationship management. Allocate approximately 25% time to (a)(i)-(ii), 35% to (b)(i)-(ii) due to numerical work, and 25% to (c), reserving 15% for diagrams and review.

  • (a)(i) Material removal via three mechanisms: direct hammering by abrasive particles, cavitation-induced erosion, and chemical action at tool-work interface; frequency 15-30 kHz, amplitude 10-50 μm
  • (a)(ii) Parameters: amplitude, frequency, static feed force, abrasive grit size, concentration, slurry viscosity; MRR ∝ (amplitude)^0.5, ∝ (frequency), ∝ (grit size) up to optimum, then decreases
  • (b)(i) ABC by annual consumption value (70-20-10 rule), VED by criticality (Vital-Essential-Desirable), SDE by availability (Scarce-Difficult-Easy); applications in Indian manufacturing context
  • (b)(ii) Calculate annual consumption value (Demand × Cost), rank descending, compute cumulative percentage: A items (top 70-80% value), B (next 15-25%), C (remaining 5-10%)
  • (c) Sourcing steps: specification, supplier identification, RFQ/bidding, evaluation (technical-commercial), negotiation, contract, performance monitoring; factors: cost, quality, delivery, reliability, geopolitical risk, Make-in-India policy alignment

Paper II

8 questions · 400 marks
Q1
50M Compulsory calculate Thermodynamics, Heat Transfer and Fluid Mechanics

(a) Consider the system shown in Fig. 1(a). The two chambers initially have equal volumes of 28 litres and contain air (C_p = 1·005 kJ/kg-K and C_v = 0·717 kJ/kg-K) and hydrogen (C_p = 14·32 kJ/kg-K and C_v = 10·17 kJ/kg-K), respectively. The chambers are separated by a frictionless piston which is non-heat-conducting. Both the gases are initially at 140 kPa and 40 °C. Heat is added to the air side until the pressure of both the gases reaches 280 kPa. All outside walls of the chambers are insulated except for the surface where heat is added to air. Calculate the final temperature of the air. (10 marks) (b) What is 'choked flow' in a convergent-divergent nozzle? Explain, with diagram, the effect of pressure ratio on exit velocity of compressible gas in a convergent-divergent nozzle. (10 marks) (c) An axial flow compressor with inlet and outlet angles of 40° and 15°, respectively has been designed for 50% reaction. The compressor has a pressure ratio of 6 : 1 and overall isentropic efficiency of 0·80, when inlet static temperature is 41 °C. The blade speed and axial velocity are constant throughout. Assuming a value of 210 m/s for blade speed, find the number of stages required if the work done factor is 0·88 for all the stages. Take Cp = 1·005 kJ/kg-K and γ = 1·4 for air. (10 marks) (d) Hot water is flowing through a pipe made of cast iron having thermal conductivity of 52 W/m-°C, with an average velocity of 1·5 m/s. The inner and outer diameters of the pipe are 3 cm and 3·5 cm, respectively. The pipe passes through a 15 m long section of a basement whose temperature is 15 °C. The temperature of the water drops from 70 °C to 67 °C as it passes through the basement. The heat transfer coefficient on the inner surface of the pipe is 400 W/m²-°C. Determine the combined convection and radiation heat transfer coefficient at the outer surface of the pipe. (10 marks) (e) (i) Define the total and spectral black body emissive powers. How are they related to each other? (5 marks) (ii) Consider two identical bodies, one at 1000 K and the other at 1500 K. Which body emits more radiation in the shorter wavelength region? Which body emits more radiation at a wavelength of 20 μm? (5 marks)

Answer approach & key points

Calculate numerical solutions for parts (a), (c), and (d) while explaining theoretical concepts with diagrams for parts (b) and (e). Allocate approximately 25% time each to (a), (c), and (d) as they involve multi-step calculations; 15% to (b) for the choked flow diagram and explanation; and 10% to (e) for definitions and Wien's displacement law application. Begin each numerical part with stated assumptions and end with unit verification.

  • Part (a): Apply first law to adiabatic hydrogen compression (γ_H2 = 1.407) to find T_H2_final, then use piston equilibrium and ideal gas law to find T_air_final ≈ 586-590 K
  • Part (b): Define choked flow as Mach 1 at throat with maximum mass flow; sketch P-V diagram showing over-expanded, design, and under-expanded nozzle conditions with exit velocity trends
  • Part (c): Use 50% reaction condition (α1 = β2, α2 = β1) to find flow angles, compute stage temperature rise from degree of reaction and velocity triangles, then determine stages n ≈ 8-9
  • Part (d): Apply thermal resistance network (convection-inner, conduction-pipe, convection+radiation-outer) using LMTD for water temperature drop, solve for h_outer ≈ 12-15 W/m²°C
  • Part (e)(i): Define E_bλ = C1λ⁻⁵/[exp(C2/λT)-1] and Eb = σT⁴ with Planck's law integration; state Stefan-Boltzmann constant σ = 5.67×10⁻⁸ W/m²K⁴
  • Part (e)(ii): Apply Wien's law (λ_maxT = 2898 μm·K) to show 1500 K body emits more at shorter wavelengths; use Planck's distribution to compare emission at 20 μm
Q2
50M calculate Thermodynamics, Heat Transfer and Compressible Flow

(a) 10 g of water at 20 °C is converted into ice at –10 °C at constant atmospheric pressure. Assuming the specific heat of liquid water to remain constant at 4·2 J/g-K and that of ice to be half of this value and taking the latent heat of fusion of ice at 0 °C to be 335 J/g, calculate the total entropy change of the system. (20 marks) (b) A shaft having diameter of 5 cm rotates in a bearing made of cast iron. The shaft rotates at 4500 r.p.m. The bearing is 15 cm long, 8 cm outer diameter and has thermal conductivity of 70 W/m-K. There is a uniform clearance between the shaft and the bearing of 0·6 mm. The clearance is filled with a lubricating oil having thermal conductivity of 0·14 W/m-K and dynamic viscosity of 0·03 N-s/m². The bearing is cooled externally by a liquid, and its outer surface is maintained at 40 °C. Disregarding the heat conduction through the shaft and assuming only one-dimensional heat transfer, determine (i) the rate of heat transfer to the coolant, (ii) the surface temperature of the shaft and (iii) the mechanical power wasted by the viscous dissipation in the lubricating oil. (20 marks) (c) Air (C_p = 1·05 kJ/kg-K, γ = 1·38) at 3 bar pressure and T = 600 K is flowing with a velocity of 180 m/s inside a 20 cm diameter duct. Calculate the— (i) mass flow rate; (ii) stagnation temperature; (iii) Mach number; (iv) stagnation pressure assuming flow to be (1) compressible and (2) incompressible. (10 marks)

Answer approach & key points

Calculate the required quantities for all three parts systematically. For part (a), compute entropy changes for cooling water, freezing, and cooling ice separately, then sum. For part (b), apply viscous dissipation in Couette flow with cylindrical coordinates, then use thermal resistance network for conduction through oil and bearing. For part (c), apply compressible flow relations for mass flow, stagnation properties, and Mach number, then compare compressible vs incompressible stagnation pressure results. Allocate approximately 35% time to (a), 40% to (b), and 25% to (c) based on complexity and marks distribution.

  • Part (a): Three-stage entropy calculation — cooling water from 20°C to 0°C (ΔS₁ = mc_w ln(273/293)), freezing at 0°C (ΔS₂ = -mL_f/T_f), cooling ice from 0°C to -10°C (ΔS₃ = mc_ice ln(263/273)); total ΔS = ΔS₁ + ΔS₂ + ΔS₃ with c_ice = 2.1 J/g-K
  • Part (b)(i)-(iii): Velocity gradient in annular gap τ = μ(du/dy) = μ(ωR_i)/c, viscous dissipation Φ = τ²/μ, heat generation Q = Φ×volume, thermal resistances R_oil = ln(R_o/R_i)/(2πk_oilL) and R_bearing = ln(R_b/R_o)/(2πk_bearingL), shaft temperature found from heat balance
  • Part (c)(i): Mass flow rate using ṁ = ρAV = (P/RT)×(πD²/4)×V with R = 287 J/kg-K for air
  • Part (c)(ii)-(iii): Stagnation temperature T₀ = T + V²/(2C_p), Mach number Ma = V/√(γRT), critical check whether flow is subsonic (Ma < 1)
  • Part (c)(iv): Compressible stagnation pressure P₀ = P(T₀/T)^(γ/(γ-1)), incompressible P₀ = P + ½ρV² using ρ = P/RT; explicit comparison showing difference
  • Unit consistency throughout: temperatures in Kelvin for thermodynamic calculations, SI units for all quantities, proper handling of kJ vs J conversion
  • Physical interpretation: negative entropy change in (a) indicates irreversibility of freezing process; in (b) recognition that viscous dissipation dominates heat generation; in (c) quantification of compressibility effects at Ma ≈ 0.37
Q3
50M prove Gas turbine, solar collector, heat transfer

(a) (i) How do the specific work output and efficiency vary with pressure ratio in a gas turbine? (ii) Prove that the efficiency of a gas turbine corresponding to the maximum work done in a Brayton cycle is given by the relation $$\eta_{w \max} = 1 - \frac{1}{\sqrt{t}}$$ where $t$ is the ratio of the maximum and minimum temperatures. (20 marks) (b) A solar collector, as shown in Fig. 3(b) below, having dimensions as 1 m wide and 5 m long, has constant spacing of 3 cm between the glass cover and the collector plate. Air enters the collector at 30 °C and at a rate of 0·15 m³/s through the 1 m wide edge and flows along the 5 m long passageway. If the average temperatures of the glass cover and the collector plate are 20 °C and 60 °C, respectively, determine (i) the net rate of heat transfer to the air in the collector and (ii) the temperature rise of air as it flows through the collector. Fig. 3(b) The properties of air at 1 atm and an estimated average temperature of 35 °C may be taken as : ρ = 1·145 kg/m³, k = 0·02625 W/m-°C, ν = 1·655×10⁻⁵ m²/s, Cₚ = 1007 J/kg-°C, Pr = 0·7268 (20 marks) (c) A windshield of a car, having dimensions as 0·6 m high and 1·8 m long, is electrically heated and is subjected to parallel winds at 1 atm, 0 °C and 80 km/hr. The electrical power consumption is observed to be 50 W, when the exposed surface temperature of the windshield is 4 °C. Disregarding the radiation and heat transfer from the inner surface and using the momentum heat transfer analogy, determine the drag force the wind exerts on the windshield. The properties of air at 0 °C and 1 atm may be taken as : ρ = 1·292 kg/m³, Cₚ = 1·006 kJ/kg-K, Pr = 0·7362 (10 marks)

Answer approach & key points

Prove the Brayton cycle efficiency relation in part (a) using calculus-based optimization; for (b) and (c), solve the numerical problems using appropriate heat transfer correlations and momentum-heat transfer analogy. Allocate approximately 40% time to part (a) due to its derivation-heavy 20 marks, 35% to part (b) for complex convection calculations, and 25% to part (c) for the Reynolds analogy application. Structure as: (a) theoretical derivation with T-s diagram, (b) step-wise Nusselt number calculation and energy balance, (c) Stanton number and drag coefficient linkage.

  • Part (a)(i): Specific work output increases with pressure ratio to a maximum then decreases; efficiency increases monotonically with pressure ratio for ideal Brayton cycle
  • Part (a)(ii): Derivation of η_wmax = 1 - 1/√t by differentiating net work w.r.t. pressure ratio, setting to zero, and substituting optimal pressure ratio r_p,opt = √t
  • Part (b): Hydraulic diameter calculation (D_h = 2b = 0.06 m), Reynolds number determination, Nusselt number using appropriate correlation (laminar/turbulent), heat transfer coefficient, and net heat transfer to air
  • Part (b): Temperature rise from energy balance Q = ṁC_pΔT, with mass flow rate from ρ and volumetric flow rate
  • Part (c): Application of Reynolds/Colburn analogy (St = Cf/2 × Pr^(-2/3)), calculation of Stanton number from heat transfer data, determination of friction coefficient and drag force
  • Part (c): Recognition that electrical power equals convective heat loss q = hA(T_s - T_∞) for establishing heat transfer coefficient
Q4
50M construct Impulse turbine, centrifugal compressor, heat exchanger

(a) A single-stage impulse turbine rotor has a mean blade ring diameter of 500 mm and rotates at a speed of 10000 r.p.m. The nozzle angle is 20° and the steam leaves the nozzles with a velocity of 900 m/s. The blades are equiangular and the blade friction factor is 0·85. Construct velocity diagrams for the blades and determine the inlet angle of the blades for shockless entry of steam. Also, determine (i) the diagram power for a steam flow of 750 kg/hr, (ii) the diagram efficiency, (iii) the axial thrust and (iv) the loss of kinetic energy due to friction. (20 marks) (b) (i) Explain the effect of impeller blade shape on the performance of a centrifugal compressor with the help of an exit velocity diagram and pressure ratio-mass flow rate curve. (ii) Discuss the phenomena of surging and choking in centrifugal compressors. (20 marks) (c) A shell and tube heat exchanger operates with two shell passes and four tube passes. The shell side fluid is ethylene glycol, which enters at 140 °C and leaves at 80 °C with a flow rate of 4500 kg/hr. Water flows in the tubes, entering at 35 °C and leaving at 85 °C. The overall heat transfer coefficient for this arrangement is 850 W/m²-°C. Calculate the flow rate of water required and the area of the heat exchanger. The specific heat of ethylene glycol may be taken as 2·742 J/g-°C and the specific heat of water may be taken as 4·175 J/g-°C. For NTU relations, the following figure may be used. (10 marks)

Answer approach & key points

Construct velocity diagrams for part (a) as the primary directive, then explain compressor phenomena for (b), and solve the heat exchanger problem for (c). Allocate approximately 40% time to (a) given its 20 marks and diagram construction demand, 35% to (b) for its dual explanatory components, and 25% to (c) for the NTU method calculation. Begin with clear velocity triangle construction for impulse turbine, follow with theoretical explanations supported by sketches, and conclude with systematic heat exchanger sizing using the correction factor method.

  • Part (a): Blade speed U = πDN/60 = 261.8 m/s; velocity triangles constructed with nozzle angle 20°, equiangular blades, and friction factor 0.85 applied to relative velocities
  • Part (a): Inlet blade angle β₁ calculated from velocity triangle geometry for shockless entry; diagram power = ṁ(V_w1 + V_w2)U, efficiency = diagram power / kinetic energy supplied
  • Part (a): Axial thrust = ṁ(V_f1 - V_f2) and friction loss = ½ṁ(V_r1² - V_r2²) computed with correct mass flow rate conversion (750 kg/hr = 0.2083 kg/s)
  • Part (b)(i): Backward-curved, radial, and forward-curved blade effects on pressure ratio-mass flow characteristics with exit velocity diagrams showing V₂, V_w2, and manometric efficiency
  • Part (b)(ii): Surging as flow reversal instability at low mass flow rates and choking as sonic limit at impeller eye; both phenomena explained with performance curve annotations
  • Part (c): Heat balance Q = ṁ_glycol × c_p,glycol × ΔT_glycol = ṁ_water × c_p,water × ΔT_water to find water flow rate
  • Part (c): LMTD calculation for counterflow arrangement, correction factor F from given figure for 2-shell pass 4-tube pass configuration, and area A = Q/(U×F×LMTD)
Q5
50M Compulsory explain IC engines, thermodynamics, refrigeration and air conditioning

(a) Can alcohols be used as fuel in IC engine? Explain with advantages and disadvantages. (10 marks) (b) A water-filled reactor with a volume of 1 m³ is at 20 MPa and 360 °C, and is placed inside a containment room as shown in Fig. 5(b). The room is well-insulated and initially evacuated. Due to a failure, the reactor ruptures and the water fills the containment room. Find the minimum room volume so that the final pressure does not exceed 200 kPa. [Use steam table data given at the end of the Paper] (10 marks) (c) Using a schematic and T-s diagram, explain how with perfect regeneration for a simple steam power plant (Rankine) cycle, thermal efficiency can approach Carnot efficiency. (10 marks) (d) Discuss the effect of the following parameters on the performance of a vapor compression refrigeration system with the help of p-h diagram: (i) Suction pressure (ii) Delivery pressure (iii) Subcooling of liquid (iv) Superheating of vapors (10 marks) (e) The room air is recirculated at the rate of 40 m³ per minute and the outdoor air enters a cooling coil of an air conditioner at 32 °C DBT and 18 °C WBT. The effective surface temperature of the coil is 4·5 °C. The surface area of the coil is such as would give 12 kW of refrigeration with the given entering conditions of air. Determine the DBT and WBT of the air leaving the coil and the coil bypass factor. [Psychrometric chart is given at the end of this Paper] (10 marks)

Answer approach & key points

Explain the suitability of alcohols as IC engine fuels with balanced advantages and disadvantages for part (a). For (b), apply first law for unsteady flow with steam tables to find containment volume. Part (c) requires schematic and T-s diagram with clear regeneration explanation. Part (d) needs p-h diagram analysis of four parameters. Part (e) involves psychrometric calculations with bypass factor. Allocate ~15% time each to (a), (c), (d); ~25% to (b) and (e) due to numerical complexity.

  • Part (a): Alcohols (methanol, ethanol) as fuels—higher octane rating, lower emissions vs lower energy density, corrosion, cold-start issues; mention India's ethanol blending programme (E20, E85)
  • Part (b): Unsteady flow energy equation for ruptured reactor; initial state: compressed liquid/subcooled water at 20 MPa, 360°C; final state: saturated mixture at 200 kPa; mass and energy balance to find quality and containment volume
  • Part (c): Rankine cycle with perfect regeneration—open feedwater heater schematic; T-s diagram showing heat addition at variable temperature approaching Carnot's isothermal; mean temperature of heat addition increases to T_max
  • Part (d): p-h diagram effects—suction pressure ↑ increases refrigeration effect and COP; delivery pressure ↑ decreases COP; subcooling ↑ increases refrigeration effect; superheating ↑ may increase or decrease COP depending on useful cooling
  • Part (e): Psychrometric process—mixing of recirculated and outdoor air, cooling and dehumidification to 4.5°C EST; bypass factor = (T_out - T_est)/(T_in - T_est); energy balance for 12 kW to find air exit conditions
  • Part (b) specific: Use steam tables—initial v ≈ 0.0015 m³/kg (compressed liquid), u ≈ 1700 kJ/kg; final v_f and v_g at 200 kPa; solve for mass then V_room = m·v_final
  • Part (e) specific: Locate 32°C DBT, 18°C WBT on chart; find humidity ratio; process follows constant sensible heat factor to 4.5°C EST; read exit DBT and WBT
Q6
50M calculate IC engine testing, regenerative steam cycle, absorption refrigeration

(a) A four-cylinder diesel engine with swept volume of 0·98 litre is tested on a performance bed. The engine running at a speed of 2500 r.p.m. against a brake with arm of 0·3 m produces brake load of 190 N with fuel consumption of 6·8 litres/hr. The calorific value of fuel is 45000 kJ/kg and specific gravity of fuel is 0·82. A Morse test is carried out on the engine by cutting off the fuel supply of individual cylinder in the order 1, 2, 3, 4 with corresponding brake loads 131 N, 135 N, 133 N and 137 N, respectively. Calculate the b.p., b.m.e.p., brake thermal efficiency, b.s.f.c., i.p., mechanical efficiency and i.m.e.p. of the engine at test speed. (20 marks) (b) A power plant operates on a regenerative steam cycle with one closed feedwater heater. Steam enters the first turbine stage at 125 bar, 500 °C and expands to 10 bar, where some of the steam is extracted and diverted to the closed feedwater heater. Condensate exiting the feedwater heater as saturated liquid at 10 bar passes through a trap into the condenser. The feedwater exits the heater at 120 bar with a temperature of 170 °C. The condenser pressure is 0·06 bar. Assuming isentropic turbine and pump work, determine the thermal efficiency of the cycle. At 125 bar, 500 °C for steam, h = 3343·6 kJ/kg and s = 6·4651 kJ/kg-K. [Use steam tables provided at the end of this Paper] (20 marks) (c) Explain NH₃-water vapor absorption refrigeration system with a neat diagram. What are the desired properties of refrigerant-absorber combination? (10 marks)

Answer approach & key points

Calculate all performance parameters for the diesel engine in part (a) using Morse test principles, then solve the regenerative steam cycle in part (b) by applying energy balance and steam table interpolation. For part (c), explain the NH₃-water absorption system with a neat schematic. Allocate approximately 40% time to (a) due to multiple calculations, 40% to (b) for steam table work, and 20% to (c) for the descriptive portion with diagram.

  • Part (a): BP = 2πNT/60 = 2π×2500×(190×0.3)/60000 = 14.92 kW; BSFC = ṁf/BP in kg/kWh
  • Part (a): IP from Morse test = Σ(indicated power of each cylinder) using BP - BPcutoff for each cylinder
  • Part (a): Mechanical efficiency = BP/IP; IMEP = IP×60/(L×A×N/2×n) or using swept volume
  • Part (b): Apply energy balance on closed feedwater heater: y×h2 + (1-y)×h6 = h7 + (1-y)×h3 for extraction fraction
  • Part (b): Determine h at turbine exit using s1 = s2 = s3; pump work h6 - h5 = v5×(P6-P5); thermal efficiency = Wnet/Qin
  • Part (c): NH₃-water system: generator, condenser, evaporator, absorber with heat exchanger; NH₃ as refrigerant, water as absorber
  • Part (c): Desired properties: high solubility of refrigerant in absorber, large boiling point difference, low specific heat of solution, non-toxic, non-corrosive, chemically stable
Q7
50M solve IC engines, air conditioning, and chimney draught

(a) (i) Briefly discuss HC, CO and NOₓ emission formation in SI engine. Explain the dependence of these emissions on equivalence ratio with a neat diagram. (10 marks) (ii) An IC engine working on an ideal Otto cycle has AFR of 15 : 1 and compression ratio of 9 : 1. The pressure and temperature at the start of compression are 1 bar and 27 °C, respectively. Find the maximum temperature and pressure of the cycle. Assume that compression process follows the law pV¹·³³ = C, the calorific value of fuel is 43000 kJ/kg and Cᵥ of working fluid is 0·717 kJ/kg-K. (10 marks) (b) A food processing room has a very high latent heat load and is required to be air conditioned as per the following data: Room design conditions : 20 °C DBT, 60% RH Outside conditions : 45 °C DBT, 30 °C WBT Room sensible heat : 35 kW Room latent heat : 20 kW The ventilation air requirement is 90 cmm Determine the (i) ventilation load, (ii) room and effective sensible heat factors and (iii) ADP and amount of reheat for economical design. Assume bypass factor of the coil as 0·05. [Psychrometric chart is given at the end of this Paper] (20 marks) (c) Prove mathematically that for maximum discharge through a chimney of a certain height and cross-section, the absolute temperature of gases bears a certain ratio to the absolute temperature of the outside atmosphere, in case of natural draught of a boiler. (10 marks)

Answer approach & key points

Solve this multi-part question by allocating time proportionally to marks: ~20 minutes for (a)(i) emissions discussion with diagram, ~20 minutes for (a)(ii) Otto cycle numerical, ~40 minutes for (b) air conditioning psychrometric calculations, and ~20 minutes for (c) chimney draught derivation. Begin each part with clear identification of given data, apply appropriate thermodynamic principles, and conclude with physically meaningful results.

  • (a)(i) HC formation via flame quenching and crevice volumes; CO from incomplete combustion in rich mixtures; NOx via thermal (Zeldovich) mechanism at high temperatures; emissions vs equivalence ratio diagram showing HC/CO peak rich, NOx peak slightly lean
  • (a)(ii) State 1: p1=1 bar, T1=300K; polytropic compression to state 2: p2=p1*(r)^1.33, T2=T1*(r)^0.33; heat addition using Q=m*Cv*(T3-T2) with fuel energy release; solve for T3 (max temp) and p3=p2*T3/T2 (max pressure)
  • (b) Plot room condition (20°C DBT, 60% RH) and outside condition (45°C DBT, 30°C WBT) on psychrometric chart; calculate ventilation sensible and latent loads; determine RSHF=RSH/(RSH+RLH) and ESHF accounting for bypass factor; find ADP from coil process line and reheat needed
  • (b) Ventilation load: mass flow rate from 90 cmm, enthalpy difference between outside and room air; split into sensible and latent components
  • (c) Derive draught pressure Δp = H*g*(ρa-ρg) = H*g*ρa*(1-Ta/Tg); discharge ṁ ∝ √(Δp/Tg); maximize ṁ w.r.t. Tg to obtain Tg/Ta = 2 for maximum discharge
  • (c) Alternative derivation using chimney height equation and differentiating discharge equation with respect to gas temperature, showing optimal temperature ratio is 2:1
Q8
50M calculate Refrigeration, combined power plant, and vapor power cycles

(a) A VCR cycle refrigerator driven by a 60 kW compressor has a COP of 6·0. The enthalpies of saturated liquid and saturated vapor refrigerant at condenser temperature of 35 °C are 114·95 kJ/kg and 283·89 kJ/kg, respectively. The saturated refrigerant vapor leaving evaporator has an enthalpy of 275·76 kJ/kg. Find the temperature of refrigerant at the exit of compressor. The Cₚ of refrigerant is 0·62 kJ/kg-K. (20 marks) (b) In a combined gas turbine-steam turbine power plant, the exhaust gas from the open-cycle gas turbine is the supply gas to the steam generator of the steam cycle at which additional fuel is burnt in the gas. The pressure ratio for the gas turbine is 7·5, the air inlet temperature is 15 °C and the maximum temperature is 750 °C. Combustion of additional fuel raises the gas temperature to 750 °C and the gas leaves the steam generator at 100 °C. The steam is supplied to the steam turbine at 50 bar and 600 °C and the condenser pressure is 0·1 bar. The total power output of the plant is 200 MW. The calorific value of the fuel burnt is 43·3 MJ/kg. Neglecting the effect of the mass flow rate of fuel on the air flow, determine (i) the flow rate of air and steam required, (ii) the power outputs of the gas turbine and steam turbine, (iii) the thermal efficiency of the combined plant and (iv) the air-fuel ratio. Take Cₚ = 1·11 kJ/kg-K and γ = 1·33 for combustion gases; and Cₚ = 1·005 kJ/kg-K and γ = 1·4 for air. Neglect pump work. Condensate enthalpy at 0·1 bar = 192 kJ/kg. [Mollier diagram is attached in Page No. 14] (20 marks) (c) Two vapor power cycles are coupled in series where heat lost by one is absorbed by the other completely. If η₁ is the thermal efficiency of the topping cycle and η₂ is the thermal efficiency of the bottom cycle, determine the efficiency of the combined cycle in terms of these efficiencies. Assume cycles to be reversible. (10 marks)

Answer approach & key points

Calculate the compressor exit temperature for part (a) using energy balance and isentropic relations; for part (b) systematically determine air/steam flow rates, power outputs, thermal efficiency and air-fuel ratio using gas turbine and steam cycle analysis with the given Mollier diagram data; for part (c) derive the combined cycle efficiency formula using reversible heat engine principles. Allocate approximately 35% time to part (a), 50% to part (b) due to its four sub-requirements, and 15% to part (c) for the derivation.

  • Part (a): Refrigeration effect = COP × Ẇ = 360 kW; mass flow rate ṁ = 360/(275.76-114.95) = 2.237 kg/s; compressor work per kg = 26.82 kJ/kg; T₂ = T₁ + (h₂-h₁)/Cp with h₂ from energy balance yielding T₂ ≈ 52-55°C
  • Part (b): Gas turbine: T₂ = T₁×(r_p)^((γ-1)/γ) = 288×2.143 = 617.3 K; T₃ = 1023 K; T₄ = T₃/(r_p)^((γ-1)/γ) = 477.4 K; heat added in combustor = Cp,g×(1023-477.4); additional heat in HRSG raises to 1023 K; steam cycle: h₁ from 50 bar/600°C using Mollier chart ≈ 3666 kJ/kg, h₂ from 0.1 bar ≈ 2260 kJ/kg (isentropic)
  • Part (b)(i): Energy balance on HRSG gives ṁ_air and ṁ_steam; ṁ_steam = 200 MW total / [(h₁-h₂) + (Ẇ_GT/ṁ_steam)] after iteration
  • Part (b)(ii): Ẇ_GT = ṁ_air×Cp,g×[(1023-617.3)+(1023-477.4)]; Ẇ_ST = ṁ_steam×(h₁-h₂)
  • Part (b)(iii): η_combined = (Ẇ_GT + Ẇ_ST)/(ṁ_fuel×CV) with total fuel in GT combustor and HRSG
  • Part (b)(iv): AFR = ṁ_air/ṁ_fuel from energy balance Q = ṁ_fuel×CV = ṁ_air×Cp,g×ΔT
  • Part (c): For reversible cycles, η_combined = η₁ + η₂ - η₁η₂ derived from Q₁→W₁+Q₂ with Q₂ = Q₁(1-η₁) and W₂ = η₂Q₂

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