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ESE-2020 : MAINS TEST SERIES

U P S C E N G I N E E R I N G S E R V I C E S E X A M I N AT I O N

MECHANICAL
ENGINEERING
Test No. 9
Section A : Machine Design + Mechatronics & Robotics (All Topics)
Section B : Power Plant (All Topics)

Time Allowed : 3 hrs. Maximum Marks: 300

Question Paper Specific Instructions

Please read each of the following instructions carefully before attempting questions:
• Answers must be written only in ENGLISH.
• There are EIGHT questions divided in TWO sections.
• Candidate has to attempt FIVE questions in all.
• Question no. 1 and 5 are compulsory and out of the remaining THREE are to be attempted
choosing at least ONE question from each section.
• The number of marks carried by a question/part is indicated against it.
• Wherever any assumptions are made for answering a question, they must be clearly indicated.
Diagrams/figures, wherever required, shall be drawn in the space provided for answering
the question itself.
• Unless otherwise mentioned, symbols and notations carry their usual standard meanings.
Attempt of questions shall be counted in sequential order. Unless struck off, attempt of a
question shall be counted even if attempted partly. Any page or portion of the page left blank
in the Question-cum-Answer Booklet must be clearly struck off.

DO NOT OPEN THIS BOOKLET UNTIL YOU ARE ASKED TO DO SO

For any query write to us, at: info@madeeasy.in
2 | ESE 2020 : MAINS TEST SERIES

Section A : Machine Design + Mechatronics & Robotics

Q.1 (a) A four-wheeled automobile car has a total mas 1000 kg. The moment of inertia of each wheel
about a transverse axis through its centre of gravity is 0.5 kg.m2. The rolling radius of the
wheel is 0.35 m. The rotating and reciprocating parts of the engine and the transmission system
are equivalent to a moment of inertia of 2.5 kg.m2, which rotates at 5 times the road-wheel
speed. The car is travelling at a speed of 100 km/hr on a plane road. When the brakes are
applied, the car decelerates at 0.5 g (g = gravitational acceleration).
There are brakes on all four wheels. Calculate :

(i) The energy absorbed by each brake and

(ii) The torque capacity of each brake.
[12 marks]

Q.1 (b) Explain the acronyms RAM, ROM, PROM, EPROM and EEPROM (or, EAPROM) with their
functions.
[12 marks]

Q.1 (c) A point P in space is defined as BP = (5, 3, 4)T relative to frame ‘B’ which is attached to the
origin of the reference frame ‘A’ and is parallel to it. Apply the following transformations to
frame B and find AP.
• Rotate 90° about x-axis then
• Translate 3 unit about y-axis 6 units about z-axis and 5 unit about x-axis. Then
• Rotate 90° about z-axis.
[12 marks]

Q.1 (d) What should be the Performance Specifications for a good Control System?
[12 marks]

Q.1 (e) (i) The mechanical representation of a system is given in the figure below. Show that the
differential equation of the system is
d2 y dy
2
+2 + 25 y = 25x
dt dt
y(t)

x(t)
K = 1000 N/m
m = 40 kg
B = 80 N.s/m

(ii) The block diagram representation of an aircraft elevator system is shown in the figure
below. Obtain the closed loop transfer function.
1
2 + 5
– s2 + s + 1

[6+6 = 12 marks]
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 Test No : 9 MECHANICAL ENGINEERING | 3
Q.2 (a) The arm with three degrees of freedom shown in figure has joints 1 and 2 perpendicular and
joints 2 and 3 parallel. As pictured, all joints are at their zero location. Note that the positive
sense of the joint angle is indicated. Assign link frames {0} through {3} for this arm – that is,
sketch the arm, showing the attachment of the frames. Then derive the transformation matrices
0 T, 1 T and 2 T.
1 2 3
L3 L4

θ1
L2

L1

θ2
^
YT
^ {T}
ZS ^
YS

θ3
^
XT
^
ZT
^
XS
[20 marks]

Q.2 (b) An accelerometer is designed with a seismic mass of 50 gram, a spring constant of 5000 N/m,
and a damping constant of 30 N.s/m. If the accelerometer is mounted to an object experiencing
displacement xin(t) = 5 sin(100t) mm, find each of the following:
(i) The actual acceleration amplitude of the object.
(ii) The amplitude of the steady state relative displacement between the seismic mass and the
housing of the accelerometer.
(iii) The acceleration amplitude, as measured by the accelerometer.
(iv) An expression for the steady state relative displacement of the seismic mass relative to the
housing as a function of time [xr(t)]
[20 marks]

Q.2 (c) A welded connection, as shown in figure is subjected to an eccentric force of 60 kN in the plane
of the welds. Determine the size of the welds, if the permissible shear stress for the weld
is 100 N/mm2. Assume static conditions.
60 kN

W1
W3
100
W2
150
50

(Dimensions shown in figure are in mm)

[20 marks]

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4 | ESE 2020 : MAINS TEST SERIES

Q.3 (a) Two rolled carbon steel plates with a dimension of l × t = 200 mm × 12 mm are joined by rivets
shown in figure. The diameter of the rivets is d = 20 mm and the pitch is w = 60 mm. The
allowable tensile stress of the plate is σ = 200 MPa. The allowable shear stress of the rivet is
τ = 150 MPa. The allowable bearing stress between the rivet and plate is σp = 300 MPa. Check
the strength of the rivet joint if a tension force of F = 300 kN is applied. If the strength is
deficient, how can the design be improved?
d

t F
F t

l w
F F

[20 marks]

Q.3 (b) Explain the principle of operation of the following transducers.

(i) Piezoelectric transducer
(ii) Hall-effect transducer
[10×2 = 20 marks]

Q.3 (c) An intermediate shaft of a gearbox, supporting two spur gears A and B and mounted between
two bearings C1 and C2, is shown in figure. The pitch circle diameters of gears A and B are
500 mm and 250 mm respectively. The shaft is made of alloy steel 20MnCr5. (Sut = 620 N/mm2
and Syt = 480 N/mm2). The factors kb and kt of the ASME code are 2 and 1.5 respectively. The
gears are keyed to the shaft. Determine the shaft diameter using the ASME code. (Assume
permissible normal stress is 0.3 times of yield strength and 0.18 times of ultimate strength,
permissible shear stress is 0.75 times of permissible normal stress of the shaft).

200

C1 208
200
572
A
416
1144

B 200

C2

(Distances shown in figure are in mm and forces are in Newton)

[20 marks]
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 Test No : 9 MECHANICAL ENGINEERING | 5
Q.4 (a) Consider the three link planar manipulator which is shown with its link parameters. As per
assigning the coordinate system the D-H parameters table mentioned below. Derive the inverse
kinematic equation.

x3

2
x
θ3

y2 y3
θ2 L2
y1 y0 x1
θ1 L1

x0

Parameters
θ d a α
Position
0–1 θ1 0 0 0
1–2 θ2 0 L1 0
2–3 θ3 0 L2 0

[20 marks]

Q.4 (b) Explain working of the following type of pressure control valves with diagram.
1. Pressure regulating (reducing) valve
2. Pressure relief (limiting) valve
3. Pressure sequence valve
[7+6+7 = 20 marks]

Q.4 (c) An electric motor supplying constant torque to a machine, whose turning moment diagram is
shown in figure. Mechanical efficiency of the drive from motor to machine shaft is 85%. Torque
first increases from 300 N.m to 1200 N.m for half revolution and then decreases to 300 N.m in
quarter revolution at 400 rpm. No load for the rest quarter revolution, coefficient of fluctuation
of speed is limited to 0.15. Density of flywheel material is 7200 kg/m3. Calculate :
(a) Power required by the motor.
(b) Mass and size of disk flywheel, if radius to thickness ratio is limited to 15. (Assume flywheel
is disc type).

C
1200
Torque (N.m)

A
E
300
F
0 0.5π π 1.5π 2π
Angle
[20 marks]
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6 | ESE 2020 : MAINS TEST SERIES

Section B : Power Plant

Q.5 (a) A gas turbine operating on actual simple Brayton Cycle is to be designed for maximum work
output. If the maximum and minimum temperatures of the cycle, the isentropic efficiencies of
compressor and turbine are fixed then derive the expression for optimum actual pressure
ratio. What will be the value of optimum pressure ratio for turbine and compressor, if the ratio
of maximum to minimum temperature is 3 and γ = 1.67? Take isentropic efficiencies of turbine
and compressor as 0.9 and 0.8 respectively.
[12 marks]

Q.5 (b) A 20 stages 50% reaction turbine develops a diagram power of 12 MW. The inlet conditions of
steam is at 15 bar, 350°C and total isentropic enthalpy drop is 855 kJ/kg. The stage efficiency
is 75% for each stage and reheat factor is 1.04. At one stage the steam is at 1 bar, dry and
saturated. The exit angle of blades is 20° and blade velocity ratio is 0.7. The blade height may
be taken as 1/12 of mean blade diameter. Calculate :
(a) The flow rate of steam required, assuming that all stages develop equal work.
(b) The mean blade diameter.
(c) The speed of the rotor.
[12 marks]

Q.5 (c) What do you understand by internally irreversible and externally irreversible Rankine Cycle?
[12 marks]

Q.5 (d) What is Babcock Wilcox boiler? Explain with figure.

[12 marks]

Q.5 (e) In a simple Brayton cycle with single stage compression and two stage expansion with perfect
reheating, derive the following expression for maximum work output.
γ −1 2 /3
γ
 T3 
r =  
T 
1

where γ is ratio of specific heat, r is compressor pressure ratio and T1 and T3 are minimum and
maximum temperature respectively.
[12 marks]

Q.6 (a) A combined gas turbine-vapor power plant operating as in figure below has a net power

gas kg/s and steam is m
output of 100 MW. Mass flow rate of air is m
vap kg/s. Air enters the
gas turbine cycle at 1 bar and 300 K. Compressor pressure ratio is 14 and the temperature of
the gas at the turbine inlet (T3) is 1700 K. Exhaust gases leave the gas turbine cycle at (T5) 400
K. The vapor power cycle operates between 60 bar and 0.06 bar. Temperature of the steam at
the turbine inlet (T7) is 500°C. Working fluid exits the condenser as a saturated liquid. Note
that P4 = P5 = P1 and P6 = P7. Use Brayton cycle to analyze gas turbine cycle and Rankine cycle
to analyze vapor power cycle.

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 Test No : 9 MECHANICAL ENGINEERING | 7
(i) Draw both these cycles on separate T-s diagrams and describe what is going on in the heat
recovery steam generator.

(ii) Calculate mass flow rate of air and steam.

(iii) Calculate the thermal efficiency of combined cycle.

(iv) Cooling water enters at (T10) 298 K and exits at (T11) 323 K. Calculate the mass flow rate of
the cooling water.

At 0.06 bar, hf = 151.4934 kJ/kg, hg = 2566.667 kJ/kg, sf = 0.5208 kJ/kgK, sg = 8.3291 kJ/kg.K,
vf = 0.001006 m3/kg
Qin

Condenser
2 3

Gas .
Compressor Turbine W gas
Turbine

Air inlet
4
1 5
Exhaust

7
Heat-Recovery
Steam Generator
.
6 Turbine W vap
[Vapor Cycle]
8
11
Condenser
Pump Cooling
10 Water
9

[20 marks]

Q.6 (b) Air enters the compressor of a gas-turbine engine at 37°C and 101 kPa. The overall pressure
ratio is 12 and heat is transferred to air in the amount of 695.3 kJ/kg before it enters the
turbine. The isentropic efficiency of compressor and turbine are 84% and 87% respectively.
Determine :
(i) Power input to the compressor
(ii) Temperature at the exit of turbine
(iii) Thermal efficiency of cycle
(iv) Entropy change in compressor
(Take mass flow rate of air as 100 kg/s and neglect mass flow rate of fuel)
[20 marks]

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8 | ESE 2020 : MAINS TEST SERIES

Q.6 (c) A sample of bituminous coal gave the following ultimate analysis by mass : C = 81.9%,
H = 4.9%, O = 6%, N = 2.3%, Ash = 4.9%. Calculate :
1. The stoichiometric A/F ratio
2. The analysis by volume of the wet and dry products of combustion when the air supplied
is 25% in excess of that required for complete combustion.
[20 marks]

Q.7 (a) Water at 30°C flows into a cooling tower at the rate of 1.15 kg per kg air. Air enters the tower
at the dbt of 20°C and a relative humidity of 60% and leaves it at a dbt of 30°C and 90%
relative humidity. Make up water is supplied at 20°C. Determine :
(i) The temperature of water leaving the tower.
(ii) The fraction of water evaporated, and
(iii) Range of the cooling tower.
Assume : At 20°C, Psat = 2.3392 kPa and at 30°C, Psat = 4.2469 kPa and Enthalpy of water is zero
at 0°C.
[20 marks]

Q.7 (b) A steam generator comprises a boiler, a superheater, an economiser and an air preheater. The
feed water enters the economiser at 140°C and leaves as saturated liquid. Air is preheated
from a temperature of 25°C to 250°C. Steam leaves the boiler drum at 60 bar, 0.98 dry and
leaves the superheater at 450°C. When using coal with a calorific value of 25.2 MJ/kg, the rate
of evaporation is 8.5 kg steam per kg coal and the air fuel ratio is 15 : 1 by mass. Neglecting
heat losses and pressure drops, estimate the heat transfer per kg fuel in each component and
the efficiency of steam generator. What are the percentages of the total heat absorption taking
place in the economiser, boiler and the superheater, respectively? Assume cP of air and water
as 1.005 kJ/kgK and 4.2 kJ/kgK, respectively.
[20 marks]
Q.7 (c) A steam power plant operates on an ideal regenerative Rankine cycle with one open feed
water heater operating at 0.125 MPa. Steam enters the first turbine stage at 15 MPa, 600°C.
Condensate exiting the feedwater as saturated liquid at 0.125 MPa. The condenser pressure is
2.5 kPa. For isentropic process in the two turbine stages and the pump, determine the following :
(i) The net work of the cycle in kJ/kg
(ii) The mass flow rate into the first-turbine stage in kg/hr, if the net power developed for
this power plant is 212 MW.
(iii) The net heat transfer into the working fluid through the boiler in kJ/kg.
(iv) The thermal efficiency of the cycle (in %).
[20 marks]

Q.8 (a) A furnace wall riser, is 18 m long, 76.2 mm OD and 6.1 mm thick receives saturated water at 80
bar and 1.5 m/s velocity. Assuming a circulation ratio of 12.5 and a slip ratio of 1.2, determine
(i) the pressure head developed, (ii) the void fraction at riser exit and (iii) the heat transfer
rate per unit projected area of the riser tube.
At 80 bar, vf = 0.001384 m3/kg, vg = 0.023524 m3/kg, hfg = 1441.3 kJ/kg
[20 marks]

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 Test No : 9 MECHANICAL ENGINEERING | 9
Q.8 (b) A boiler plant incorporates an economizer and air preheater and generates steam at 40 bar and
300°C with fuel of heating value 33000 kJ/kg burned at a rate of 500 kg/h. The temperature of
feed water is raised from 40°C to 125°C in the economizer and the flue gases are cooled at the
same time from 395°C to 225°C. The flue gases then enter the air preheater in which the
temperature of combustion air is raised by 75°C. A forced draught fan delivers the air to the
air preheater at a pressure of 1.02 bar and a temperature of 16°C with a pressure rise across the
fan of 180 mm of water. The power input to the fan is 5 kW and it has a mechanical efficiency
of 78%. Neglect heat losses.
Caclulate :
(i) Mass flow rate of air
(ii) Temperature of flue gases leaving the plant
(iii) Mass flow rate of steam
(iv) Efficiency of the boiler
(Take cP = 1.01 kJ/kgK for flue gases and cp = 1.005 kJ/kgK for air)
[20 marks]

Q.8 (c) An open cycle gas turbine plant operates with a pressure ratio of 5.0 while 75 kg/min of air
and 1.8 kg/min of fuel. The net electrical power output from the plant is 210 kW when the
power needed to drive compressor is 240 kW. Air enters the compressor at 1 bar and 17°C and
combustion gas enters the turbine at 777°C. Assuming specific heat of air and combustion
gases as 1.005 kJ/kgK and 1.3 kJ/kgK respectively. The isentropic index of compression (γair) is
1.4 and isentropic index of expansion (γgas) is 1.35 and mechanical efficiency for both compressor
and turbine is 0.98 while for shaft between turbine and generator is 0.95. Estimate
(i) The isentropic efficiency of compressor
(ii) The isentropic efficiency of turbine and
(iii) The overall efficiency of the plant
[20 marks]

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 Test No : 9 MECHANICAL ENGINEERING

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ESE 2020 : MAINS TEST SERIES

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 Test No : 9 MECHANICAL ENGINEERING

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ESE 2020 : MAINS TEST SERIES

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