Elements of Mechanical Engineering

MODULE-II: HYDRAULIC TURBINES, BOILERS AND PUMPS

Prime movers are the mechanical devices which convert the energy obtained by the natural
resources into useful mechanical energy. Prime movers are classified into two types. They are
a. Thermal prime movers : Steam turbine, Gas turbine and Heat engine
b. Hydraulic prime movers : Water Turbines

WATER TURBINES:
A Water turbine is defined as a prime mover in which the hydraulic energy of the
water is transformed into mechanical energy in the form rotary motion.

Classification water turbines:

The water turbines are classified on the following criteria:
1. According to hydraulic action as
a. Impulse turbine
b. Reaction turbine
2. According to the head of source of water as
a. High head turbine
b. Medium head turbine
c. Low head turbine
3. According to direction of flow of water as
a. Tangential flow turbine
b. Radial flow turbine
c. Axial flow turbine
d. Mixed flow turbine
4. According to the position of shaft as
a. Horizontal shaft turbine
b. Vertical shaft turbine
5. According to the discharge of water as
a. High discharge turbine
b. Low discharge turbine

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Pelton Wheel:

Pelton wheel is a high head, tangential flow impulse turbine shown in fig 2.10. It consists
of a rotor, on the periphery of which the double hemispherical buckets are evenly spaced and
fitted. Water is transferred from a high head source through a penstock which is fitted with a
nozzle. Through the nozzle, the water flows out as a high speed jet. The nozzle is provided with
spear rod. A hand wheel is fitted to the spear rod so as to move the spear rod to and fro in order
to get a desired size of jet of water. The jet of water at a high velocity impinges the buckets. As a
result of impingement the runner rotates, supplying power to the shaft. After performing the
work on the buckets the water discharges freely into the tail race.
Francis turbine:

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Francis turbine shown in fig2.11 is a medium head, mixed flow reaction turbine. It
consists of a spiral casing enclosing a number of stationary guide blades fixed all round the
circumference of inner ring of moving vanes forming the runner which is keyed to the turbine
shaft.
Water at high pressure enters through the inlet in the casing and flows radially inwards to
the outer periphery of the runner through the guide blades. From the outer periphery of the
runner the water flows inwards through the moving vanes and discharges at the centre of the
runner at lower pressure. During its flow over the moving blades it imparts kinetic energy to the
runner to set it into rotational motion. To enable the discharge of water at lower pressure, a
diverging conical tube called draft tube is fitted at the centre of the runner. The other end of the
draft tube is immersed in the discharging side of the water known as tail race.

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Kaplan turbine:

Kaplan turbine shown in fig 2.12 is a low head, axial flow reaction turbine. It consists of
a spiral casing, a ring of guide blades, a runner and a draft tube. The runner of a Kaplan turbine
called boss or hub and it resembles the propeller of a ship. Hence the Kaplan is also sometimes
called propeller turbine.
The water at high pressure enters the turbine casing through the inlet and flows over the
guide blades. The water from the guide blades strikes the runner blades axially imparting the
kinetic energy to set it into rotational motion. The specialty of this turbine is the runner vanes
and their motion during the runner rotation. The specially designed vanes facilitate smooth flow
of water to the tail race through a draft tube, while the runner is in motion.

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Differences between impulse and reaction hydraulic turbines:

Sl Impulse turbine Reaction turbine

No
1 The entire hydro energy is converted into Only a part of the hydro energy is
kinetic energy converted into kinetic energy and the rest
remains as pressure head
2 Draft tube is not necessary Draft tube is necessary
3 The water jet strikes a few buckets at a The water is guided by the guide blades
time with kinetic energy to flow over the blades with pressure
energy
4 The pressure of the flowing water remains The pressure of the flowing water
constant throughout decreases after gliding over the blades
5 The runner need not run full The runner should always run full and
submerged in water
6 It is possible to regulate the flow without It is not possible to regulate the flow
loss without loss
7 Losses, if discharge is low No losses even if the discharge is low

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BOILERS:
Boiler or steam generator is a device used to create steam by applying heat energy to
water. Although the definitions are somewhat flexible, it can be said that older steam generators
were commonly termed boilers and worked at low to medium pressure (6 to 2000kPa) but, at
pressures above this, it is more usual to speak of a steam generator.
There are two general types of boilers: ''fire-tube'' and ''water-tube''.

Water-tube boilers:
A water tube boiler is such kind of boiler where the water is heated inside tubes and the
hot gasses surround them. This is the basic definition of water tube boiler. Actually this boiler is
just opposite of fire tube boiler where hot gasses are passed through tubes which are surrounded
by water.
Examples: Bobcock & Wilcox boiler.

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Advantages of Water Tube Boiler:

 Larger heating surface can be achieved by using more numbers of water tubes.
 Due to convectional flow, movement of water is much faster than that of fire tube boiler,
hence rate of heat transfer is high which results into higher efficiency.
 Very high pressure in order of 140 kg/cm2 can be obtained smoothly.
Fire-tube boilers:
A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or
(many) more tubes running through a sealed container of water. The heat of the gases is
transferred through the walls of the tubes by thermal conduction, heating the water and
ultimately creating steam.
Examples: Vertical, Cochran, Lancashire and Locomotive boilers.

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Lancashire boiler:

Lancashire boiler is a stationary, fire tube boiler which is constructed for normal working
pressure up to 15 bar and 8500 kg of steam per hour. This boiler is widely used in sugar mills
and chemical industries.

Figure 1.6
Construction:
The cylindrical shell is placed horizontally over brickwork and partly (3/4th) filled with
water. The water level inside the boiler should be above the furnace tube which is constructed
inside the drum as in figure 1.6

Two large tubes called furnace or flue tubes extend throughout the length of boiler drum.
In each flue tubes two furnace greats are provided inside for burning fuel with ash pit at their rear
end. The diameter of these flue tubes are made about 0.3 to 04 times of the boiler, in order to get
in grates of sufficient area for burning. The brick work setting provides enclosed chamber for
each of the flue tubes at the rear end of the boiler shell, which in turn connected to side channels

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1 & 2 at their front end. The two side channels are connected to their rear end to a common rear
passage which is connected to chimney.

Working:
The fuel is charged on grates and burned with a large quantity of air to produce hot gases.
Initially the first run of hot gas passes inside the drum and from front end to rear end. During
this heat transfer takes place from hot gas to water along the walls of the flue tubes.The hot
gasses then emerge to rear enclosed chamber in the rear end, then pass downwards and unite.
Now in second run hot gases pass from bottom portion of the boiler shell to bottom central
channel. After second run hot gases divide at the front end of boiler shell and enters side channel
1 & 2 for third run. During the third run hot gasses pass through side channels to rear end of
boiler and make their exit to chimney. During third run heat transfer takes place between hot
gas and water through a portion of boiler shell exposed to side channel. Finally, steam
accumulates in the boiler shell and can be taken out through stop valve.The boiler is mounted
with essential mountings and accessories like stop valve, safety valve, blow off valve, pressure
gauge, water gauge etc with super heater if required.

Babcock and Wilcox boiler:

Babcock and Wilcox boiler is a stationary, water tube, natural circulation boiler. It has a
capacity to produce steam up to 40 bar and 4000 kg / hour. This type of boiler is used in thermal
power plants, etc.

Construction and working:

This boiler mainly consists of,
 Water tubes
 Water and steam drum
 Chain grate stoker
 Super heater
 Mud box

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Water tubes: Water tubes are placed between the furnace at an inclined position which
connect uptake and down take. The drum is connected at the front end to uptake and at backend
to down take. The fire brick baffles make the hot gases to move in the upward direction then
downward and again upward before leaving through chimney.
Water and steam drum: A horizontal drum is placed above the water tubes and is half
filled with water and steam remains on other half. The portion of water tubes which is just above
the furnace is heated more compared to others, the water density increases and rises to drum
through the uptake where steam particles separate from water and collect over water surface. The
water from drum comes down through down take into water tubes and move up again to drum
through uptake, by this circulation of become continues.
Chain grate stoker: - The high capacity boilers are generally provided with chain grate
stoker. It has slowly moving endless chain of grate bars and coal is feed at the front end of grate
and burnt while moving on grate in furnace and residual ash will falls at other end.

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Super heater: - Boilers are fitted with a set of super heater tubes which is placed just
under the drum and above water tubes. Steam is taken from steam space of boiler through which
tubes and super heated by receiving additional amount of heat by exiting hot gases. Super heated
steam finally comes out of stop valve mounted over drum.
Boiler Mountings and Accessories:

Boiler Mountings:
The fittings and devices required for the steam boilers for their safe performance are
called Boiler Mountings. Water level indicator and pressure gauge are the examples for boiler
mountings.
(i) Water level indicator or Water gauge: Its function is to indicate the level of water
inside the boiler shell.
(ii) Safety valves: Their function is to maintain safe pressure inside the boiler.
(iii) Fusible plug: Its function is to protect the boiler from explosion due to overheating
caused on account of low water level.
(iv) Pressure gauge: Its function is to indicate the pressure of the steam inside the boiler.
(v) Steam Stop valve or Junction valve: Its function is to regulate the flow of steam
from boiler to the engine whenever necessary and to shut-off the steam flow when not
required.

Boiler Accessories:
The auxiliary plants required for the steam boilers to increase their efficiency are called
Boiler Accessories. Super heater and air preheater are the examples for boiler accessories.

(i) Super heater: Its function is to absorb the heat from the hot flue gases and superheat
the saturated steam without changing its pressure.
(ii) Air Preheater: Its function is to transfer heat from the flue gases to the air fed to the
furnace for combustion purpose.
(iii) Economizer: Its function is to heat the feed water using exhaust flue gases.
(iv) Feed water heater: The function of feed water heater is to increase the temperature
of the feed water before it enters the boiler.

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(v) Steam trap: The function of steam trap is to automatically drain away the condensed
steam from pipes, steam jackets and steam separators without allowing any steam to
escape.

HYDRAULIC PUMPS:

 Pump is defined as a mechanical device that rotates or reciprocates to move fluid from one
place to another.
 The function of a pump is to convert mechanical energy into hydraulic energy.
 Mechanical energy is delivered to the pump using an electric motor.
 When a hydraulic pump operates, it performs two functions.
 First, its mechanical action creates a vacuum at the pump inlet which allows atmospheric
pressure to force liquid from the reservoir into the inlet line to the pump.
 Second, its mechanical action delivers this liquid to the pump outlet and forces it into the
hydraulic system.

Need of a Pump

 Used to pump a liquid from lower pressure area to a High pressure area.
 To increase Flow rate.

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Classification of Hydraluic Pumps

Fig: Classification of Hydraulic Pumps

1. Positive Displacement pumps:

 Positive displacement pumps supplies a fixed amount of fluid by using a reciprocating piston,
or by rotating members
 Positive Displacement pumps apply pressure to the liquid by using a reciprocating piston, or
by rotating members
Different Types of positive Displacement Pumps:

a. Reciprocating pump
b. Rotary pump
 Reciprocating pumps move the fluid using reciprocating pistons or plungers
 Rotary pumps move the fluid by using rotating elements like gears, screws, vanes or cam

2. Hydrodynamic Pumps Or Non Positive displacement pumps:

 These pumps are also called as Roto-dynamic pumps or Non positive displacement pumps

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 In theses pumps dynamic force or centrifugal force causes the fluid movement from one
place to another.

Different Types of Hydrodynamic Pumps:

a. Centrifugal pumps
b. Axial flow pumps
c. Mixed flow pumps
Let us discuss the working of Reciprocating pump and centrifugal pump

1. RECIPROCATING PUMP:

IDC ODC

Fig: Reciprocating Pump

RECIPROCATING PUMP:

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A pump which conveys the water from one place to another place with the help of linear motion
of piston or plunger

Components of Reciprocating Pump

 Connecting Rod
 Piston
 Cylinder
 Suction Pipe
 Suction Valve
 Delivery Pipe
 Delivery Valve
 Sump

CONSTRUCTION OF RECIPROCATING PUMP:

Crank:

 It is mounted on the crank shaft.

 It is driven by either I.C. Engine or electric motor.
Connecting Rod:

 It connects the piston and the crank.

 It converts the rotary motion of crank into reciprocating motion of piston.
Piston

 It reciprocates inside the cylinder.

 It creates pressure difference inside the cylinder.
Suction Pipe:

 It conveys the water from sump to the cylinder

Delivery Pipe:

 It conveys the water from cylinder to the discharge tank.

Suction Valve

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 Suction valve is non-return valve which means only one directional flow is possible in this
type of valve.
 This is placed between suction pipe inlet and cylinder.
 During suction of liquid it is opened and during discharge it is closed.
Delivery Valve

 Delivery valve also non-return valve placed between cylinder and delivery pipe outlet.
 It is in closed position during suction and in opened position during discharging of liquid.
Sump:

 It is the reservoir of liquid from which water will be pumped.

WORKING OF RECIPROCATING PUMP:

1. SUCTION STROKE:
 When the crank rotates from I.D.C to O.D.C in clockwise direction, the piston moves from
left to right side
 Hence vacuum is created inside the cylinder
 Because of vacuum, liquid will come from sump to the cylinder through suction valve
 When crank reaches O.D.C., the piston is on right most position and the cylinder is full of
liquid.

2. DELIVERY STROKE:
 When the crank rotates from O.D.C to I.D.C in clockwise direction, the piston moves from
right to left side
 Hence piston exerts pressure on the liquid.
 The pressurized water is then discharged to delivery tank through discharge pipe
 At the end of delivery stroke, the crank comes to I.D.C. Now the pump has completed one
cycle.
 The same cycle repeated as the crank rotates

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USES( APPLICATIONS) OF RECIPROCATING PUMP

 Reciprocating pump is mainly used for

 Oil drilling operations
 Pneumatic pressure systems
 Light oil pumping
 Feeding small boilers condensate return

2. CENTRIFUGAL PUMP:
Centrifugal pump:Centrifugal pump is a hydraulic machine which converts mechanical energy
into hydraulic energy (i.e. pressure energy) by the use of centrifugal force

Main Parts of Centrifugal Pump:

The various main parts of a centrifugal pump are:

a. Impeller
b. Casing
c. Suction pipe with a foot valve and strainer
d. Delivery pipe

Fig: Centrifugal Pump

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a. Impeller
 It is the heart of the pump. It consists of a number of curved blades
 It is fitted on a shaft. The shaft is connected to an external electric motor.
 The motor rotates the impeller with the help of the shaft

b. Casing
 The airtight chamber surrounding impeller is called casing.
 The area of the casing gradually increases towards the pump outlet
 Because of this design of Casing, the kinetic energy of the fluid is converted into pressure
energy according to Bernoulli’s Principal
c. Suction Pipe:
 It conveys the water from sump to the pump
d. Delivery Pipe:
 It conveys the water from pump to the discharge tank or desired location

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Working of Centrifugal pump:

Working of Centrifugal Pump:

 When the electric motor starts rotating, the impeller of pump also rotates
 The rotation of the impeller creates suction at the suction pipe.
 Due to suction created, water from sump enters to the pump through the centre, or eye of the
impeller
 The impeller rotates at very high speedinside the casing
 Due to rotation of impeller, centrifugal force is developed

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 This centrifugal-force, accelerates(increases velocity) the water radially outwards into pump
casing
 The area of the casing gradually increases towards the pump outlet ( As area increases,
velocity decreases and pressure increases)
 Hence the velocity of the water keeps on decreasing and the pressure increases in the casing
according to Bernoulli’s Principal
 Now high pressure water goes to its desired location through delivery pipe.

Application of Centrifugal Pump

 The centrifugal pump is used in almost every field to raise the liquid from low level to high
level.
 They are mostly used at home for filling water tanks, almost in every industry such as
chemical, automobile, marine, manufacturing, for irrigation etc.

PRIMING OF PUMP

 Priming the pump means removing all the trapped air from the suction line of the pump and
filling the pump with water before starting
 If air is not removed from the suction line of pump, then a small negative pressure is created
at the suction pipe and it cannot suck the water from the water sump.
 So it is advised to fill the pump with water before starting it
 This is usually achieved by filling water through a connection which is close to the discharge
side manually or through an automated system.
 After this the pump can be operated normally.

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PUMP CAVITATION:
Air or vapor
bubbles

Impeller

Fig: Pump cavitation

 Cavitation is the formation of air bubbles or vapor bubbles in water

 When the pressure of water at suction side is too low(less than vapor pressure), some of the
water will vaporize, forming vapor bubbles in the water
 The vapor bubblesenter into the pump.
 As the pressure in the pump increases, the air bubbles(vapor bubbles) collapses or bursts and
it creates a high energy shock wave inside the pump
 The shockwaves travel hit the impeller and causing mechanical damage, noise and vibration
which can ultimately lead to pump failure
 Cavitation is a common problem for centrifugal pumps
 If you hear strange noises coming from thepump, there is a chance cavitation

Pump Cavitation can cause following problems:

 Failure of pump housing

 Destruction of impeller
 Excessive vibration
 Higher than necessary power consumption
 Fluctuation in discharge pressure
 Fluctuations in flow rate of water

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