UNIT-III

Definition of steam power plant:

Steam power plant is defined as a power station, where we generate electricity using a steam-driven
electric generator.
or
Thermal power plant also called thermal power station or steam power plant is used to generate
electricity.

Working principle of a thermal or steam power plant

In thermal power plants, the heat energy obtained from the combustion of fuel (coal/natural gas/other
carbon base fuel) is used to convert water into steam. The high temperature and pressure steam are used to
rotate the turbine blade; turbine shaft is connected to generator. The generator converts the kinetic energy into
electric energy.
In a steam boiler, the water is heated up by burning the fuel in the air in the furnace, and the function
of the boiler is to give dry superheated steam at the required temperature. The steam so produced is used in
driving the steam turbines. This turbine is coupled to synchronous generator (usually three-phase synchronous
alternator), which generates electrical energy. The exhaust steam from the turbine is allowed to condense into
the water in steam condenser of turbine.

Advantages of steam power plants:

1. Fuel used is cheaper.
2. They can respond quickly with changes in load on the plant.
3. Space required is less compared to hydro power plants.
4. A portion of steam can be used as process steam for various industries.
5. Cost of electric power generation and its initial cost is less compared to diesel plants.

Disadvantages of steam power plants:

1. Operation and maintenance cost is high.
2. Time needed for errection of plant is high.
3. Large quantity of water is needed.
4. Coal and ash handling poses a serious problem.
5. The part load efficiency is low.
6. Pollution causes health problems to workers and habitants near the thermal power plant.
What is diesel power plant?
Diesel power plants are standby power plants. The diesel engine is used as the prime mover to generate
electrical energy. Whereas diesel engine is used as the prime mover for the production of electrical energy that
is called diesel power plant. Basically, to generate mechanical energy diesel burns inside the diesel engine, and
the products of this combustion act as the working fluid. The diesel engines are coupled with an alternator if the
diesel engine or prime mover rotates alternator also rotates and then produces electrical energy.

Diesel power plant components:

1. Diesel Engine.
2. Fuel Supply System.
3. Engine Air Intake System.
4. Diesel engine Exhaust System.
5. Generator System.
Working principle of diesel power plant:
The working of diesel power plant or basic working principle of diesel power plant is that thermal
energy is converted into mechanical energy. This mechanical energy is converted into electrical energy to
generate electricity using generators or alternators. Basically, a diesel power plant works on four main stages
such as compression, combustion, expansion, and cooling. A diesel engine works as a prime mover diesel is
burned inside these combustion engines and products act as working fluids for the production of mechanical
energy. Diesel engines run an alternative that converts mechanical power into electrical power.
Advantages of diesel power plant:
1. The layout of the diesel power plants is very simple.
2. The diesel power plant occupies a small place.
3. It can be started quickly and picked load within a very short time.
4. The diesel power plant has no standby losses.
5. It requires a small quantity of water to cool.
6. Diesel power plant requires less staff.
7. The thermal efficiency is higher than the steam power plants.
Disadvantages of diesel power plant:
1. Diesel power plants have high running costs than hydroelectric power plants.
2. The diesel power plant does not work successfully to meet the overload condition for a longer period,
due to higher fuel costs and low generation power.
3. It generates a small amount of electrical energy.
 4. The operating cost is very high.
5. Maintenance costs are also very high.
What is hydroelectric power plant?
A power plant that utilizes the potential energy of water for the generation of electrical energy is
known as a hydroelectric power plant. Hydroelectric power plants are generally located in hilly areas where
dams can be built easily, and large water reservoirs can be made. In a hydropower plant, a water head is created
by building a dam across a river or lake. From the dam, water is fed to a water turbine.

Working principle of hydroelectric power plant:

The water turbine changes the kinetic energy of the falling water into mechanical energy at the turbine
shaft. In simple words, falling water spins the water turbine. The turbine drives the alternator coupled with it
and converts mechanical energy into electrical energy. This is the basic “working principle of hydroelectric
power plant.”
Hydroelectric power plants are very popular because the stores of fuels (i.e., oil and coal) are
exhausting day by day. They are also beneficial for irrigation and flood control purposes.
Advantages of Hydroelectric power plant:
1. More reliable power plant.
2. Low operating cost.
3. Low starting time.
4. High production rate capacity.
5. The fuel cost is zero.
6. Pollution-free.
7. Renewable source of energy.
8. Life of the power plant is more.
9. They are also used for flood control and irrigation.

Disadvantages of Hydroelectric power plant:

1. Capital cost is high.
2. Output depends upon the availability of water.
3. Commonly found in hill-areas.
4. Apparatus needs corrosion protection.
Nuclear power plant:
As we all heard about different types of power plants which are used for power generation by using
different kinds of fuels like steam power plant, hydro power plant etc. like all of these power plants one type of
power plant which is developing very fast is known as Nuclear power plant. Nuclear power plant has same
applications like other power plants i.e. to generate electricity but the major difference in the type of fuel used.
Here we use radioactive fuel like uranium. Nuclear reactor is the heat source of nuclear power plant. This heat
is used to generate steam which runs the turbine.

Components of nuclear power plant:

1. Fuel roads.
2. Control rods.
3. Moderator.
4. Coolant.
5. Steam turbine.
6. Generator.
7. Condenser.

Fuel roads: Fuel roads are fuel element used in the nuclear reactor. Here radioactive material is used as fuel.
Uranium and plutonium is the main elements used in nuclear reactors. Isotopes of uranium and plutonium are
used in chain reaction during nuclear fission. The shape and size of the fuel roads are selected according to the
design of reactor so that uniform heat should be produced in the reactor.
Control rods: It controls the energy generated by the chain reaction of the neutrons. These are in the shape of
fuel roads. The chain reaction can easily control by these rods by pushing them down. These roads have neutron
absorbing materials like boron, cadmium and indium. They have high neutron absorption capacity.
Moderator: Moderator helps in the slow down the chain reaction within the reactor. Moderator is a type of
material which slows down the neutron of atom from high kinetic energy to low kinetic energy very rapidly. It
helps to maintain the proper speed of the chain reaction. Some commonly used moderators with natural uranium
are graphite and heavy water.
Coolant: The main purpose of the coolant is to transfer the heat which produces in the reactor. Coolant cool
dawn the reactor to avoid melting and destruction. In some cases this coolant is used in the heat exchanger for
further utilization in steam generation. A good coolant should not absorb the neutron and should have high
chemical and radiation stability. Some commonly used coolants are water, heavy water and some organic
liquids etc.
Steam turbine: The steam turbine house is separated from the nuclear reactor but the steam goes through the
turbine may be radioactive. Steam turbine converts heat energy of the steam into mechanical work. Only dry
steam is enters in to steam turbine. Steam from the steam generator is allowed to goes in the turbine. This steam
turbine is further coupled with the generator.
Generator: Generator converts mechanical energy from turbine into electric energy. Power is generated by the
generator which is further transmitted for various applications.
Condenser: Condenser is a type of heat exchanger. The steam from the turbine outlet is being condensed into
the condenser. Mostly shell and tube type heat exchanger is used. Here phase change of the water takes place.
Sometimes cooling tower is used for condensing the steam in case of large power plants. This condensed water
is again circulated by using feed water supply pump.

Working principle of nuclear power plant:

The working of nuclear power plant is almost same as the thermal power plants but only difference in
the procedure of generating steam and fuel used. Here steam is generated by using radioactive fuel i.e. uranium.
A fission reaction takes place in the nuclear reactor which release large amount heat due the chain reaction of
uranium atom. This chain reaction continuously going on and large amount of heat generated. This heat is used
for various applications. In nuclear power plant this heat is used for generate steam. Now a day’s mostly two
types of nuclear power plants are under operation which are boiling water reactor power plant and pressurized
water reactor power plants.

Advantages of nuclear power plant:

1. A single unit of a Nuclear power plant can be able to produce large amount of electricity as compare to
other power plant when they are working as their full load.
2. The nuclear power plant is that it not creates air pollution.
3. Nuclear power plants produce is less carbon emission as compare to other power plants.
4. Nuclear power plant has economic necessity due to the increasing price and depletion of fossil fuels.
5. Nuclear fuel is a best alternatives option of all these fossil fuel.
6. Nuclear power plant generates electricity at cheaper rate as compare to other power plants.

Disadvantages of nuclear power plant:

1. The waste of nuclear power plant is the major issue.
2. It is very difficult to dispose it safely.
3. The waste product of the nuclear power plant can be used for the making of nuclear bombs.
4. The cost of the fuel i.e. uranium is very high and it is not easily available.
5. There are very limited sources of radioactive material.
6. The initial cost of nuclear power plant is very high.
7. Nuclear power generation face many social issues due to its safety hazards.

Robotics:
Robotics is an applied engineering science that has been referred to as a combination of machine tool technology and
computer science. It includes machine design, production theory, micro electronics, computer programming & artificial
intelligence.
OR
"Robotics" is defined as the science of designing and building Robots which are suitable for real life application in
automated manufacturing and other non-manufacturing environments.
OR
Industrial robot is defined as an automatic, freely programmed, servo controlled, multi-purpose manipulator to handle
various operations of an industry with variable programmed motions.
Specifications of robotics:
1. Axel of motion
2. Work stations
3. Speed
4. Acceleration
5. Pay load capacity
6. Accuracy
7. Repeatability etc…
Advantages of robotics:
1. High Production rates
2. Lead time decreases
3. Storing capacity decreases
4. Human errors are eliminated.
5. Labour cost is decreases.

Disadvantages of robotics:
1. Initial cost of raw material is very high,
2. Maintenance cost is high,
3. Required high skilled Labour.
4. Indirect cost for research development & programming increases.

Applications of robots:
1. Present Applications of Robots
1. Material transfer applications
2. Machine loading and unloading
3. Spot welding
4. Continuous arc welding
5. Spray coating
6. Drilling, routing, machining operations
7. Grinding, polishing debarring wire brushing
8. Laser drilling and cutting etc.
9. Assembly tasks, assembly cell designs, parts mating.
10. Inspection, automation.
2. Future Applications of Robots
1. Mechanical design
2. Household robots
3. Fire fighting operations
4. Robots in space
5. Security guards
6. Universal gripper
 7. Mobility and navigation (walking machines)
8. FMS (Flexible Manufacturing Systems)
9. Hazardous and inaccessible non-manufacturing environments
10. Medical care and hospital duties etc.

Classification of Robots:
The robots can be classified according to the configuration, types of control, drive, movement, application,
degree of freedom and sensory system.
1. Physical Configuration
1. Cartesian coordinate configuration
2. Cylindrical coordinate configuration
3. Polar coordinate configuration
4. Jointed arm configuration
5. SCARA.
2. Control System
1. Point to point robots
2. Straight line robots
3. Continuous robot
3. Movement
1. Fixed robot
2. Mobile robot
3. Walking or legged robot

4. Types of Drive
1. Pneumatic drive
2. Hydraulic drive
3. Electric drive
5. Application
1. Manufacturing
2. Handling
3. Testing
6. Degrees of Freedom
1. Single degree of freedom
2. Two degree of freedom
3. Three degree of freedom
4. Six degree of freedom
7. Sensory Systems
1. Simple and blind robot
2. Vision robot
3. Intelligent robot
8. Capabilities of Robot System
1. External robot control and communication
2. System parameters
3. Program control
4. Control for the end effectors
5. Program debug and simulation
6. Ability to move between points in various ways

Co-ordinate system:
Industrial robots are available in a wide variety of sizes, shapes, and physical configurations. The vast majority
of today’s commercially available robots possess one of the basic configurations:
 1. Polar configuration
2. Cylindrical configuration
3. Cartesian coordinate configurable
4. Jointed-arm configuration
1. Polar configuration: Polar/Spherical robots are robot configurations with a combined linear joint and two rotary joints,
with an arm connected to a robotic base and a twisting joint. Also known as spherical robots, the axes create a spherical
work envelope and a polar coordinate system. They are well-known in the history of robotics.

Advantages:
1. Simple design
2. High payloads
3. Light in weight.
4. Easy to programme.
5. Good precision.
6. Larger work envelope than Cartesian or cylindrical.
Disadvantages:
1. Lower mechanical rigidity.
2. More sophisticated control system than Cartesian or cylindrical.
3. Limited vertical movement.
4. Positional error is proportional to the radius at which the arm is operating.
Applications:
1. Injection moulding
2. Forging
3. Machine toot loading
4. Material transfer

2. Cylindrical configuration: Cylindrical configuration consists of a vertical column, relative to which an arm assembly
is moved in and out relative to the axis of the column. Common configuration is to use a T-joint to rotate the column
about it axes.

Advantages:
1. Rigid structure.
2. Easy to program off-line.
3. Good repeatability and accuracy.
4. Suitable for pick and place operations.
5. Larger work envelope than cartesian configuration.
Disadvantages:
1. Lower mechanical rigidity.
2. Repeatability and accuracy lower in direction of rotary movement.
3. More sophisticated control system required than cartesian.
4. Horizontal motion is circular only.
 5. Restriction on the compatibility with other types of arms common workspace.
Applications:
1. Load/unload.
2. Conveyor pallet transfers.
3. Material transfer.

3. Cartesian coordinate configurable: Cartesian robots are also called rectilinear or gantry robots and have a rectangular
configuration. These types of industrial robots have three prismatic joints to deliver linear motion by sliding on its three
perpendicular axes (X, Y and Z).

Advantages:
1. Rigid structure.
2. Simple controls.
3. Easy to visualize.
4. Easy to program off-line.
5. High degree of mechanical rigidity.
6. Good accuracy and repeatability.
7. Consistent payloads throughout work envelope.
Disadvantages:
1. Limited in movement.
2. Requires large floor space for the large structure.
3. Can only reach in front of itself.
4. Restriction on the compatibility with other types of arms in a common workspace.
Applications:
1. Assembly
2. Surface finishing.
3. Inspection

4. Jointed-arm configuration: This type of joint is often used in robotic arms and legs, where it enables movements such
as bending and straightening. The design of a revolute joint typically involves a motor, which provides the rotational
force, and a series of gears, which transmit this force to the joint.

Advantages (Revolute)
1. Most flexible.
2. Flexible reach.
3. Versatile configuration.
4. Larger work envelope.
 5. Most anthropomorphic.
Disadvantages (Revolute)
1. Sophisticated controller is required.
2. Complex programming.
3. Different locations in work envelope determine accuracy.
4. Most complex manipulator.
5. Less stable as arm approaches maximum reach.
6. Most difficult to control.
7. Accuracy can be poor.
Applications
1. Automatic assembly.
2. In-process inspection.
3. Machine vision.
4. Painting and welding.

Robot joints:
1. Linear joint.
2. Rotational joint.
3. Twisting joint.
4. Revolving joints.

1.Linear joint: Prismatic joints are also known as sliding as well as linear joints. They are called prismatic, because the
cross section of the joint is considered as a generalized prism.They permit links to move in a linear relationship.In some
cases, adjoining links are perpendicular, but one link slides at the end of the other link.The joint motion is defined by
sliding or translational movements of the links.

2.Rotational joint: It is identified by its motion, rotation about an axis perpendicular to the adjoining links. Here, the
lengths of adjoining links do not, but the relative position of the links with respect to one another changes as the rotation
takes place.

3. Twisting joint:It is also a rotational joint, where the rotation takes place about an axis that is parallel to both adjoining
links.

4. Revolving joint:It is another rotational joint, where the rotation takes place about an axis that is parallel to one of the
adjoining links. Usually, the links are aligned perpendicular to one another at this kind of joint. The rotation involves
revolution of one link about another.

Robot links:
1.Rigid link: In this type of link, there will not be any deformation while transmitting the motion.
2.Flexible link: In this type of link, there will be a partial deformation while transmitting the motion.
3.Fluid link: In this type of link, motion is transmitted with the help of fluid pressure.

Belt Drive
A belt drive is a frictional drive that transmits power between two or more shafts using pulleys and an elastic belt. In most cases,
it is powered by friction but it may also be a positive drive. It can operate at wide ranges of speed and power requirements. It is
also highly efficient.

Types of Belt Drives

1. Open belt drive
2. Closed or crossed belt drive
3. Fast and loose cone pulley
4. Stepped cone pulley
5. Jockey pulley drive
6. Quarter turn belt drive
7. Compound belt drive
Types of Belts
1. Round belt
2. Flat belt
3. V belt
4. Toothed belt
5. Link belt
Advantages
1. Belt drives is the low component cost and high efficiency.
2. They can transmit power over long distances.
3. Compared to chain drives, they operate smoother and more quietly.
4. They can absorb shock and vibrations.
5. Overload protection through the slipping of the belt.
6. Lightweight and relatively durable.
7. Low maintenance costs.
Disadvantages
1. Belt slippage can vary the velocity ratio.
2. They apply a heavy load on the bearings and shafts.
3. It is low speed range.
4. Short service life if not maintained well.
5. Power loss due to slip and creep.
Applications Of Belt-Drive
1. The belt drive is used in the Mill industry.
2. The belt drive is used in Conveyor.
3. Power transmission in industrial machinery and equipment
4. Automotive applications, in different types of engines and transmissions
5. Agricultural machinery, such as tractors and harvesters
6. Conveyor systems in manufacturing and distribution facilities
7. Power tools, such as table saws and drill presses.
Chain Drive:
Chain drive is a type of mechanical power transmission system that uses chains to transfer power from one place to another. A
conventional chain drive consists of two or more sprockets and the chain itself. The holes in the chain links fit over the sprocket
teeth.

Types of Chains
1. Hoisting Chains
2. Conveyor Chains
3. Power transmission Chains
Types of Chains in Use
1. Roller chain (bush roller chain)
2. Silent chain or inverted tooth chain
3. Leaf chain
4. Flat-top chain
5. Engineering steel chain

Advantages of Chain drive

1. Low maintenance.
2. Greater efficiency up to 97%.
3. Slipping is negligible
4. Chain drives can operate in wet conditions too.
5. It can withstand abrasive conditions.
6. The chain drives is easy to install.
7. Initial tension is not required in chain drives.
8. Even in fire hazards it does not faces any problem.
9. Multiple shafts can be driven from a single chain drive.
10. Transmit higher power as compared to belt drive.
11. The speed ratio is good as compared to belt drive.
Disadvantages of Chain drive
1. It requires more frequent lubrication otherwise rusting problems can arise.
2. It cannot be used where there is a requirement of slips.
3. We can’t keep chain drives in open. It needs housing or covering.
4. It cannot be used for applications that require precise motion requirements.
5. It is noisy and therefore there is a problem of vibration too.
6. The installation or initial cost is more.
7. The velocity fluctuation is more.
Application of chain drive
 Chain drive is used for high transmission of power.
 It is used for lifting loads and also used to carry heavy materials.
 This is also used in woodworking machinery.
 Transportation Industry.
 Agriculture Machinery.
 Material Handling Equipment.
 Building construction.
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 Rope Drive

1. Wire ropes.
2. Fibre ropes.
Advantages of Rope Drive
1. Appreciable power transmission.
2. Used for long-distance power transitions.
3. Strong and flexible ropes.
4. Smooth and noise resistant.
5. Runs in any direction.
6. Low-cost and economical.
7. Precise alignment of the shaft is not needed.
Disadvantage of Rope Drive
1. Failure of rope does not have any sign, so it often gets unnoticed.
2. Wire rope gets corroded.
Application of Rope Drive
Rope drive is found having various applications which can be used for several purposes like
1. Hunting.
2. Pulling.
3. carrying purposes.
4. lifting purposes.
Gear drives:
Gear drives are packaged units used for a wide range of power-transmission applications. They are used to transmit power
to a driven piece of machinery and to change or modify the power that is transmitted.

Types of gear trains:

1. Simple gear trains
2. Compound gear trains
3. Reverted gear trains
4. Epicyclic gear trains

Types of gear drives

1. Spur Gear.
 2. Helical Gear.
3. Double Helical Gear.
4. Herringbone Gear.
5. Bevel Gear.
6. Worm Gear.
7. Hypoid Gear

Advantages of gear drives

1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It has high efficiency.
4. It has reliable service.
5. It has compact layout.
Disadvantages of gear drives
1. The manufacture of gears require special tools and equipment.
2. The error in cutting teeth may cause vibrations and noise during operation.
Applications of gear drives
1. automotive transmission systems,
2. wheel differentials,
3. marine equipment,
4. turbines,
5. gear motors.