Laboratory Manual

Heat Transfer Operations Lab

(CHE325)

Lab In-charge : Dr. Abdul Razzaq

Lab Advisor : Engr. M. Akmal Rana

Department of Chemical Engineering

COMSATS University Islamabad, Lahore Campus

 TABLE OF CONTENTS

I. Author Notes ------------------------------------------------------------ii

II. Learning outcomes of course ------------------------------------------iii

III. Safety Rules and Regulations -----------------------------------------iv

IV. Instructions for preparing laboratory reports/books ----------------vi

V. Evaluation/ Grading of the overall lab -------------------------------vii

VI. List of Experiment ------------------------------------------------------viii

 I. Author Notes

Heat Transfer Operations Lab enables the students to apply the understanding of heat transfer
mechanisms such as conduction, convection and radiation for understanding the performance
of various heat transfer equipment such as heat exchangers, condensers, boilers, evaporators
etc. used in almost all the chemical and related industries. The HTO lab manual concentrates
on the concepts involved in modes of heat transfer i.e. conduction, convection and radiation,
heat transfer by convection (Natural & Forced Convection), the application of dimensional
analysis like Reynold, Prandtl and Nusselt, Biot, Rayleigh, grashoff number to convection,
radiation mode of heat transfer and its applications, the concept of film and overall
heat transfer coefficients, Heat Exchanger types and relevant parameters such as pressure
drop control and heat loss control.
Text Book:
1. Coulson & Richardson’s chemical engineering J. M. Coulson, J. F. Richardson –
1996
2. Unit operation of chemical engineering Warren Lee McCabe, Julian Cleveland Smith,
Peter Harriot McGraw-Hill, 2005 - Technology & Engineering
Reference Book:
1. Heat transfer: a problem solving approach Adrian Bejan, Allan D. Kraus – 2003
2. Heat Transfer Jack Philip Holman – 2009

ii
II. Learning outcomes of course

Heat Transfer Operations Lab encourages students to understand the basic concepts of
heat transfer mechanism by performing different heat transfer equipment given under
different case studies and varying the experimental parameters. Commonly used heat
transfer equipment such as various types of heat exchangers, evaporators, film wise/drop
wise condensation, conduction through heating rods and composite wall, radiation heat
transfer module and unsteady state head conduction equipment enable students to signify
the working principle of basic heat transfer equipment being used in different chemical
industries and also enable them to trouble shoot in case of equipment failure. The HTO
lab also persuade students to develop and analyze different heat exchanger systems to
develop concepts and techniques for academic research, deal with issues associated to the
operation of computer controlled heat transfer systems in chemical industries and
optimizing the performance of the equipment.

iii
III. Safety Rules and Regulations

1. As in most HTO lab experiments we are dealing with hot water and steam so contact
lenses are not allowed. Even when worn under safety goggles, hot fumes may
accumulate under the lens and cause serious injuries.
2. Closed toe shoes and long pants must be worn in the lab. Sandals and shorts are not
allowed as any mishandled hot fluid can cause injury to naked body surface.
3. Long hair must be tied back when using open flames such as in free/forced convection
and geyser to avoid burning of hair.
4. Eating, drinking, and smoking are strictly prohibited in the laboratory.

4. No unauthorized experiments are to be performed. If you are curious about trying a

procedure not covered in the experimental procedure, consult with your laboratory
instructor.
5. Never taste anything. Never directly smell the source of any vapor or gas; instead by
means of your cupped hand, waft a small sample to your nose. Do not inhale these
vapors but take in only enough to detect an odor if one exists.
6. Coats, backpacks, etc., should not be left on the lab benches and stools. There is a
hook rack along the back wall at either end of the lab. There are coat racks just inside
the each entrance to the balance room at the back of the lab. Beware that lab
chemicals can destroy personal possessions.
7. Always wash your hands before leaving lab.
8. Learn where the safety and first-aid equipment is located. This includes fire
extinguishers, fire blankets, and eye-wash stations.
9. Notify the instructor immediately in case of an accident.

11. If hot surface come into contact with your skin or eyes, flush immediately with
copious amounts of water and consult with your instructor.
12. Never point a test tube or any vessel that you are heating at yourself or your neighbor-
-it may erupt like a geyser.
13. Use gloves while operating any heat transfer equipment.

iv
IV. Instructions for preparing laboratory reports/books

Each experiment should include following

• Title of experiment
• Objective
• Theory/Concept/Background including relevant pictures
• Procedure
• Observation - Data analysis, discussion
• Useful data/charts/tables
• Safety measurement associated with each experiment
• Application
• References

v
V. Evaluation/Grading of the overall lab

The assessment of this module shall have following breakdown structure

First Sessional Test 10%

Second Sessional Test 15%
Quizzes/Assignments 25%
Terminal Examination 50%
The minimum pass marks for each course shall be 50%. Students obtaining less than 50%
marks in any course shall be deemed to have failed in that course. The correspondence
between letter grades, credit points, and percentage marks at CIIT shall be as follows:
Grades Letter Grade Credit Points Percentage Marks
A ( Excellent) 4.0 90and above
A- 3.7 85-89
B+ 3.3 80-84
B (Good) 3.0 75-79
B- 2.7 70-74
C+ 2.3 65-69
C (Average) 2.0 60-64
C- 1.7 55-59
D (Minimum passing) 1.3 50-54
F (Failing) 0.0 Less than 50

vi
VI. List of Experiments

Experiments 1: Free and Forced Convection

1. To study the effect of cooling on the heated metallic block under

a) Free convection
b) Force convection.
2. To calculate the convection heat transfer coefficient using dimensionless numbers
and compare the results in both cases.

Experiment 2: Temperature Distribution in Cylindrical Rods

1. To study the heat transfer conduction of materials with different thermal conductivity.
2. To verify the value of “Q” is higher in materials with higher conductivity.

Experiments 3: Heat conduction through Composite Wall

1. To study the effect of heat transfer through composite wall

2. Sketching the different possible temperature profile for the composite wall

Experiments 4: Double Pipe Heat Exchanger

1. Compare values of experimentally determined overall heat transfer coefficient with

theoretically calculated values for double pipe heat exchanger with
2. Steam condensing outside horizontal 1-inch diameter pipe with water flowing inside the
pipe under turbulent conditions.
3. Discuss the effect of variation of pipe diameter, steam pressure, and water flow on the
efficiency of the exchanger under study.

Experiments 5: Radiation Heat Transfer Module

1. To study the effect of radiation on different bodies (Black/Silver)

2. To prove the Stefan Boltzmann law

Experiments 6: Open Pan Evaporator

To Study the effect of steam pressure on the economy of the open pan evaporator

Experiments 7: Drop Wise and Film wise Condensation

1. To study the effect of cold stream flow rate on the rate of steam condensation.
2. To determine the individual film transfer coefficients in case of smooth and rough pipe.
3. To compare the experimental and theoretical values of the overall heat transfer coefficient
in the case of
a. Film wise condensation
b. Drop wise condensation

vii
Experiments 8: Geyser

1. To evaluate the heat transfer efficiency of geyser in case of baffle installation

2. Calculation of geyser heat transfer efficiency in case of baffle and non-baffle equipment

Experiments 9: Unsteady Heat Transfer Module

To study the effect of unsteady state heat transfer module

Experiments 10:
Shell and Tube Heat Exchanger

Compare values of experimentally determined overall heat transfer coefficient with

theoretically calculated values for Shell and Tube Heat Exchanger.

Experiments 11:
To Measure the thermal Expansion Co-efficient

viii
 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 1

FREE AND FORCED CONVECTION

Objective

1. To study the phenomena of free and forced convection.

2. To find the convective heat transfer coefficient using dimensionless
numbers in both cases and compare them.
Theory
Convection:
“Convection is the mode of energy transfer between a solid surface and the
adjacent liquid or gas that is in motion, and it involves the combined effects
of conduction and fluid motion”.

The faster the fluid motion, the greater will be the convective heat transfer. In the absence of
any bulk fluid motion, heat transfer between a solid surface and the adjacent fluid is by pure
conduction. The presence of bulk motion of the fluid enhances the heat transfer between the
solid surface and the fluid, but it also complicates the determination of heat transfer rates.
Consider the cooling of a hot body by blowing cool air over its top surface. Heat is
transferred by the air adjacent to the block by conduction. The heat is then carried away from
the surface by convection, that is by the combined effects of the conduction within the air is
due to random motion of the air that removes the heated air near the surface and it replaces it
by the cooler air.

Newton’s Law of cooling:

Despite the complexity of convection, the rate of convection heat transfer is observed to be
proportional to the temperature difference and is conveniently expressed by Newton’s law of
cooling.
𝑄𝑐𝑜𝑛𝑣 = ℎ𝐴𝑠 (𝑇𝑤 − 𝑇∞ )
Where,
h is the convective heat transfer co-efficient on W/m2.K,
As is the surface area through which convection heat transfer takes place,
Ts is the surface temperature,
T∞ is the temperature of the fluid far from the surface

Prepared By: Engr. M. Akmal Rana Page | 1

 Heat Transfer Operation Lab Manual

Free and forced Convection:

The convection heat transfer may be classified according to the nature of fluid flow. Forced
convection occurs when the flow is caused by external means, such as a fan, a pump and
similar. An example is a fan which provides forced convection air cooling of hot electrical
components on a printed circuit board.

In contrast, for the Natural (or free) convection, the flow is induced by buoyancy forces,
which arise from density differences caused by temperature variations in the fluid. In such
situation, air that makes contact with the hot components experiences an increase in
temperature and therefore reduction in density. Since the warm air is now lighter than
surrounding air, buoyancy forces induce a vertical motion and the hot air rising from the
boards is replaced by the inflow of air at room temperature. Boiling and condensation are also
grouped under general subject of convection heat transfer with the application of the
dimensional analysis convection heat transport can be defined in term of Nusselt number.
Where the Nusselt number and other dimensionless numbers for convective heat transfer are
co-related with the following equation:

Nu =f (Gr, Re, Pr) …………. (i)

Where,
Nu =Nusselt number (ratio of actual heat transfer to that by the conduction over thickness l)
Pr =Prandtl number (ratio of momentum diffusivity to that by the thermal diffusivity)
Re=Reynolds number (ratio of inertial forces to that of viscous forces)
Gr=Grashof number (ratio of buoyant forces to that viscous forces)
Ra = Rayleigh Number = (Gr*Pr)

For condition in which only natural convection occurs the velocity is dependent solely on the
buoyancy effects, represented by the Grashof number and the Reynolds number can be
omitted and equation (i) is reduced to:

Nu = f (Gr,Pr)

When forced convection occurs the effects of natural convection are usually negligible and
Grashof number may be omitted and equation (i) is reduced to:

Prepared By: Engr. M. Akmal Rana Page | 2

 Heat Transfer Operation Lab Manual

Nu = f (Re,Pr)
All fluid properties are evaluated at film temperature (Tf), where

Tf= (𝑇𝑤 + 𝑇∞ )/2

For perfect ideal gases, the expansion co-efficient β = 1/ Tf , while for liquids and non-ideal
gases the expansion co-efficient must be obtained from property charts.
For all range of Rayleigh number the following formula may be used.

For turbulent flow Ra>109 and For laminar flow Ra < 109

Formula for Forced Convection

For all range of Re # and Pr# following correlation may be used

General Description of Free and Forced Convection Equipment

The apparatus consists of a metallic block of specific dimensions (thickness, height etc) with
a thermometer installed at the top for temperature measurements. The block is heated to a
certain temperature and then allowed to cool under open air. The same procedure is repeated
under forced convection phenomena by cooling it under some external source such as fan.
The change in temperature is noted and heat transfer co-efficient is calculated to evaluate
which mode of convective heat transfer is more favored i.e. forced or free.

Procedure

1. Startup

 Insert the metallic block properly on the burner or heat source.

• Turn on the burner flame.

• Make sure that the block is exposed completely to the burner flames covering all the
below side.

2. Operation
• Note down the room temperature
• Take the metallic block and place it on the stand.
• Place the thermometer in the small cavity present at the top surface of block. Place the

Prepared By: Engr. M. Akmal Rana Page | 3

 Heat Transfer Operation Lab Manual

thermometer in cavity after filling it with Aluminum powder.

• Heat the metallic block up to 250(°C), with the help of burner.
• Remove the burner and let the block to cool down in still air (i.e. without fan)
condition.
• Note the temperature of block at suitable time interval (e.g. 30 sec or 1.0min).Until
the temperature of the block becomes equal to room temperature.
• Alternately you can record the time after every 10°C decrease in temperature.
3. Shutdown

• After performing the experiment remove the block from burner when it is at room
temperature.
• Make sure that burner is properly off with no gas leakage.
Safety and Precautions
1. Don’t start the burner till the block is properly placed on it.
2. Incase the temperature exceeds from the required temperature switch off the burner.
3. Use gloves to operate the equipment.
4. Don’t exposed naked skin to hot surface it can cause serious injury.
5. Learn where the safety and first-aid equipment is located. This includes fire extinguishers,
fire blankets, and eye-wash stations.
6. Notify the instructor immediately in case of an accident.
7. If hot surface come into contact with your skin or eyes, flush immediately with copious
amount of water and consult with your instructor.

Work Problem

A fluid flows over a plane surface 1 m by 1 m. The surface temperature is 50oC, the fluid
temperature is 20oC and the convective heat transfer coefficient is 2000 W/m2oC. The
convective heat transfer between the hotter surface and the colder air can be calculated as

q = (2000 W/(m2oC)) ((1 m) (1 m)) ((50 oC) - (20 oC))

= 60000 (W) = 60 kW

Application
This mechanism is found very commonly in everyday life, including central heating, air
conditioning, steam turbines and in many other machines. Forced convection is often
encountered by engineers designing or analyzing heat exchangers, pipe flow, and flow over a
plate at a different temperature than the stream.

References

 RC Chemical Engineering by J.M. Coulson & J.F. Richardson 6th Edition (414-416)
 Heat Transfer by J.P, Holman 9th Edition (9-11) & (205-209)
 Process Heat Transfer by D.Q. Kern Indian Edition (25-34)

Prepared By: Engr. M. Akmal Rana Page | 4

 Heat Transfer Operation Lab Manual

Observations & Calculations

Room Temperature = TR =
Length of metallic block = L =
Diameter of the metallic block = d =
Heat Transfer area (surface area) of the body = A =

Film Properties of Air at Film Value of Dimensionless Numbers Value of “h” Value of “h”
S.No Time Temperature Temperature Temperature in free in forced
( Mins ) (0C) (0C) convection convection

ρ Cp K μ Pr# Gr Ra Re
=Gr*Pr

1
2
3
4
5
6
7
8
9

Prepared By: Engr. M. Akmal Rana Page | 1

 Heat Transfer Operation Lab Manual

Air Properties chart

Prepared By: Engr. M. Akmal Rana Page | 1

 Heat Transfer Operation Lab Manual

Pre Lab Activity Experiment #1 Free and Forced Convection

Describe the following after reading the Introduction section.

Q. Describe hypothesis and goals of experiment.

Q.2 Describe experimental processes and methods.

Prepared By: Engr. M. Akmal Rana Page | 2

 Heat Transfer Operation Lab Manual

Q.3 Specify equipment, accessories and PPEs.

Prepared By: Engr. M. Akmal Rana Page | 3

 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 2

TEMPERATURE DISTRIBUTION IN CYLINDRICAL RODS

Objective
1. To study the heat transfer conduction of materials with different thermal conductivity.
2. To determine the heat transfer efficiency for each material

Theory

“Heat” is the form of energy that can be transferred from one system to another as a result of
temperature difference. The science that deals with the rates of such energy transfers is “heat
transfer”.
There are three modes of heat transfer:
1. Conduction
2. Convection
3. Radiation
Conduction:
“Conduction is the transfer of energy from the more energetic
particles of a substance to the adjacent less energetic ones as a
result of interactions between the particles”.

Conduction can take place in solids, liquids, or gases.

In Gases and liquids:
It is due to the collisions and diffusion of the molecules during their random motion.

In solids:
It is due to the combination of vibrations of the molecules in a lattice and the energy transport
by free electrons.
The rate of heat conduction through a medium depends on the
1. Geometry of the medium
2. Its thickness
3. the material of the medium
4. and the temperature difference across the medium

Fourier’s Law of heat conduction:

𝐴𝑟𝑒𝑎 × 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒
𝑅𝑎𝑡𝑒 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ∝
𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝑇1 − 𝑇2 ∆𝑇
𝑄𝑐𝑜𝑛𝑑 = 𝑘𝐴 = −𝑘𝐴
∆𝑥 ∆𝑥

Where,
k is the thermal conductivity of the material,
A is the cross sectional area,
Prepared By: Engr. M. Akmal Rana Page | 4
 Heat Transfer Operation Lab Manual

∆T is the temperature difference

∆x is the change in length.(Distance from the heater)

General Description of Heat conduction through Metallic Rod Equipment

The apparatus consists of a heating assembly which can heat three metallic rods at same time.
The metallic rods should be same in dimensions to evaluate the effect of thermal conductivity
or K on the heat transfer process. The rods are attached linearly with one end attached to the
heating assembly and other end open in air. Three thermometers are installed at equal
distances to measure the temperature gradient through the metallic rods.
Procedure

1. Startup
• Install the three metallic rods with the heating assembly.
• Note down the dimensions of the metallic rods and hang thermometers at equal
distance to measure metallic rods temperature.
2. Operation
• Switch on the heating system and set specific required temperature.
• At regular time intervals note down the temperature reading at different points along
the length of the available rods.
• Repeat the same procedure for 10 readings.
3. Shutdown
• After performing the experiment turned off the heating system
• Remove all the metallic rods when they reach rooms temperature.

Prepared By: Engr. M. Akmal Rana Page | 5

 Heat Transfer Operation Lab Manual

Observation & Calculation

For Copper rod:
Diameter ID = , OD =
Length L1 = L2 = L3 =
Temperature (○C) Temperature (○C) Temperature (○C)
Sr. # Time (min)
“T1” “T2” “T3”

For Aluminum rod:

Diameter ID = , OD =
Length L1 = L2 = L3 =
○ ○
Temperature ( C) Temperature ( C) Temperature (○C)
Sr. # Time (min)
“T1” “T2” “T3”

For SS rod:
Diameter ID = , OD =

Length L1 = L2 = L3 =
Time Temperature (○C) Temperature (○C) Temperature (○C)
Sr. #
(min) “T1” “T2” “T3”

Comparison:
Copper Aluminum S.S
Sr. #
L1 Q L1 Q L1 Q

Trend Lines

 Temperature Vs Length of the tubes

 Rate of Heat Transfer Vs Length of the tube
 Rate of Heat Transfer Vs Time
Safety and Precautions
1. Don’t note the reading till the heating system required temperature is attained.
2. In case of high temperature then required switch off the heating system.
3. Use gloves to operate the apparatus.
4. Don’t exposed naked skin to hot metallic rod as it can cause serious injury.
5. Learn where the safety and first-aid equipment is located. This includes fire extinguishers,
fire blankets, and eye-wash stations.
6. Notify the instructor immediately in case of an accident.

Prepared By: Engr. M. Akmal Rana Page | 6

 Heat Transfer Operation Lab Manual

7. If hot surface come into contact with your skin or eyes, flush immediately with copious
amounts of water and consult with your instructor.

Application
Heat transfer is an essential process throughout a number of residential, industrial and
commercial facilities. Within these locations, heat must efficiently and effectively be added,
removed or transferred from one process to another. Heat transfer is one of the most
important industrial processes. Throughout any industrial facility, heat must be added,
removed, or moved from one process stream to another. Understanding the basics of the heart
of this operation is key to any engineers' mastery of the subject.

References

 RC Chemical Engineering by J.M. Coulson & J.F. Richardson 6th Edition (387-401)
 Heat Transfer by J.P, Holman 9th Edition (1-9) & (25-35)
 Process Heat Transfer by D.Q. Kern Indian Edition (6-13)
 http://www.cheresources.com/content/articles/heat-transfer/basics-of-industrial-heat-
transfer

Prepared By: Engr. M. Akmal Rana Page | 7

 Heat Transfer Operation Lab Manual

Pre Lab Activity Experiment #2 Temperature Distribution in cylindrical

rods

Q. Describe hypothesis and goals of experiment.

Q.2 Describe experimental process and methods.

Prepared By: Engr. M. Akmal Rana Page | 8

 Heat Transfer Operation Lab Manual

Q.3 Specify equipment, accessories and PPEs.

Prepared By: Engr. M. Akmal Rana Page | 9

 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 3

HEAT CONDUCTION THROUGH COMPOSITE WALL

Objective
1 To study the effect of heat transfer through composite wall
2. Sketching the different possible temperature profile for the composite wall

Theory
Conduction (heat transfer by diffusion) is the transport of energy from the more energetic to
the less energetic particles of a substance due to a temperature gradient, and the physical
mechanism is that of random atomic and molecular activity. For one-dimensional, steady-
state heat conduction in a plane wall with no heat generation, temperature is a function of the
x coordinate only and heat is transferred exclusively in this direction.

Figure-1: Heat transfer through a plane wall

The heat transfer rate (qx) by conduction through a plane wall is directly proportional
to the cross sectional area (A) and the temperature difference (T), whereas it is inversely
proportional to the wall thickness (x).

In addition to single plane wall, heat transfer through composite wall is also
important. Such walls may involve any number of series and parallel layers made of different
materials. In the case of steady state one-dimensional heat conduction with no heat
generation, temperature profile through each layer becomes linear as shown in Figure 2. Heat
transfer through composite systems is usually described by an overall heat transfer
coefficient. Simply, the overall heat transfer coefficient is related to the total thermal
resistance.

Prepared By: Engr. M. Akmal Rana Page | 10

 Heat Transfer Operation Lab Manual

Figure-2: Heat transfer through composite systems.

General Description of Heat conduction through Composite wall

Equipment
The apparatus consists of metallic walls of different materials combined in series to evaluate
the overall heat flow through the composite wall. The first wall is attached to a heating
system at one end receiving heat from heat source and transferring to other combined metal
walls through conduction.

Procedure

1. Startup
• Place the metallic walls in series in the composite wall apparatus.
• Turn on the heating source.
• Set the temperature up to 250 o C.
2. Operation
• Wait and let the steady state be achieved.
• After certain time note down the temperature of all three walls.
• By using Fourier’s law of heat conduction, note down the heat transfer co-efficient.
3. Shutdown
• Repeat the experiment following the same procedure for another composite wall
rearranging the sequence of metallic walls.
• After performing the experiment turned off the heating system.
• Remove the metallic walls from the apparatus when they reach to room temperature.

Prepared By: Engr. M. Akmal Rana Page | 11

 Heat Transfer Operation Lab Manual

Observation & Calculation

Length from A  B  L1 
Length from B  C  L2 
Length from C  D  L3 
Thickness of Stainless Steel = X1 =
Thickness of Aluminum = X2 =
Thermal conductivity of glass wool =
Thermal conductivity of air =
Thermal conductivity of S.S. =
Thermal conductivity of Aluminum =
Temperature at point = T1 =
Temperature at point = T2 =
Temperature at point = T3 =
Temperature at point = T4 =
Rate of Heat transfer Q is given as:

T (T1  T4 )
Q  
R  L1 L L X X 
 K A  b K A  c K A  1 K A  2 K A
 gw gw gw S .S . A 

Safety and Precautions

1. Don’t switch on heating system till the walls are properly placed.
2. Don’t turn off apparatus until required temperature is attained by the heating system
3. Use gloves to operate the open pan evaporator.
4. Don’t exposed naked skin to hot water or steam as it can cause serious injury.
5. Learn where the safety and first-aid equipment is located. This includes fire extinguishers,
fire blankets, and eye-wash stations.
6. Notify the instructor immediately in case of an accident.

Application

Composite walls allow us to use any combination of material which results in the
optimization of the heating system with minimum heat losses. It allows us to change the
materials as per our requirement to meet our requirements from strong to less heating as
required for heat sensitive compounds. The resultant composite wall becomes more strong
and efficient.

References
 http://www.foundationcoalition.org/resources/en/engr214/Chapter7/node13.html
 Process Heat Transfer by D.Q. Kern Indian Edition (14-15)
 files.gj297.webnode.com/200000121-e5bd7e6bb7/HMT%20lab%20manual.pdf

Prepared By: Engr. M. Akmal Rana Page | 12

 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 4

DOUBLE PIPE HEAT EXCHANGER

Objective

1. Find out the amount of heat supplied by the steam to the cold water in a
double pipe heat exchanger.
2. Estimate the heat losses in the double pipe heat exchanger system.
3. Find out the efficiency of double pipe heat exchanger in co current flow
arrangement.
Theory

Temperature can be defined as the amount of energy that a substance has. Heat exchangers
are used to transfer that energy from one substance to another. In process units it is necessary
to control the temperature of incoming and outgoing streams. These streams can either be
gases or liquids. Heat exchangers raise or lower the temperature of these streams by
transferring heat to or from the stream.

“Heat exchangers are a device that exchange the heat between two fluids of different
temperatures that are separated by a solid wall. The temperature gradient, or the
differences in temperature facilitate this transfer of heat.”
Transfer of heat happens by three principle means:
 Radiation
 Conduction
 Convection
In the use of heat exchangers radiation does take place. However, in comparison to
conduction and convection, radiation does not play a major role. Conduction occurs as
the heat from the higher temperature fluid passes through the solid wall. To maximize
the heat transfer, the wall should be thin and made of a very conductive material. The
biggest contribution to heat transfer in a heat exchanger is made through convection.
The double-pipe heat exchanger is one of the simplest types of heat exchangers. It is called a
double-pipe exchanger because one fluid flows inside a pipe and the other fluid flows
between that pipe and another pipe that surrounds the first. This is a concentric tube
construction. Flow in a double-pipe heat exchanger can be co-current or counter-current.
There are two flow configurations:
 Co-current
It is when the flow of the two streams is in the same direction.

Prepared By: Engr. M. Akmal Rana Page | 13

 Heat Transfer Operation Lab Manual

 Counter current
It is when the flow of the streams is in opposite directions.

Effect of changing the conditions on heat transfer rate:

As conditions in the pipes change: inlet temperatures, flow rates, fluid properties, fluid
composition, etc., the amount of heat transferred also changes. This transient behavior leads
to change in process temperatures, which will lead to a point where the temperature
distribution becomes steady. When heat is beginning to be transferred, this changes the
temperature of the fluids. Until these temperatures reach a steady state their behavior is
dependent on time.

In this double-pipe heat exchanger a hot process fluid flowing through the inner pipe transfers
its heat to cooling water flowing in the outer pipe. The system is in steady state until
conditions change, such as flow rate or inlet temperature. These changes in conditions cause
the temperature distribution to change with time until a new steady state is reached.
The new steady state will be observed once the inlet and outlet temperatures for the process
and coolant fluid become stable. In reality, the temperatures will never be completely stable,
but with large enough changes in inlet temperatures or flow rates a relative steady state can
be experimentally observed.
Working Principle:
The basic principle of heat exchanger is the transfer of heat between two fluids. Two fluids
are brought in close contact with each other but are prevented from mixing by a physical
barrier. The temperature of the two fluids will soon come to an equilibrium temperature.

The energy from each fluid is exchanged and no extra heat is added or removed. Since the
heat in the process is not constant and the heat amount of the fluids is also not constant thus
the Heat exchanger must be designed in a way that it is suited for all the cases of heat
exchange and the performance is best suited for all conditions. Also the design should be

Prepared By: Engr. M. Akmal Rana Page | 14

 Heat Transfer Operation Lab Manual

such that the heat exchange is at a particular rate required by the process. Heat exchangers are
originally designed to be over sized so that in cases of fouling, the surface of heat exchanger
is still large enough to carry out operations. Once cleaned the heat exchanger would be again
oversized.
For the use of any heat exchanger the proper study of various technical and economical
parameters is required such as life of heat exchanger, cost per unit area , Overall Heat
Transfer Coefficient , Low heating value of fuel, Effectiveness, Efficiency , Heat Capacities,
Annual variation of temperatures of fluid under observation.
Various types of heat exchanger follow this general principle. Whether it isa Double Pipe
heat exchanger or Shell and Tube or Plate Heat exchanger or others of various kinds the
underlying principle is same although specifics differ greatly.
Some factors that influence the heat exchanger performance are:
 width of the material of the tubes
 Temperature variation between two fluids
 Thermal Conductivity of the material of fabrication
 Physical features of the exchanger and Surface Area of the tubes
 Type of flow i.e. Counter current or co current or mixed flow
 Properties of the liquid i.e. viscosity, Heat capacity etc.

Explanation:

As with any process the analysis of a heat exchanger begins with an energy and material
balance. Before doing a complete energy balance a few assumptions can be made. The first
assumption is that the energy lost to the surroundings from the cooling water or from the U-
bends in the inner pipe to the surroundings is negligible. We also assume negligible potential
or kinetic energy changes and constant physical properties such as specific heats and density.
These assumptions also simplify the basic heat-exchanger equations.

The determination of the overall heat-transfer coefficient is necessary in order to determine

the heat transferred from the inner pipe to the outer pipe. This coefficient takes into account
all of the conductive and convective resistances (k and h, respectively) between fluids
separated by the inner pipe, and also takes into account thermal resistances caused by fouling
(rust, scaling, i.e.) on both sides of the inner pipe. For a double-pipe heat exchanger the
overall heat transfer coefficient, U, can be expressed as
U=Qh/A.ΔTLMTD

In a heat exchanger the log-mean temperature difference is the appropriate average

temperature difference to use in heat transfer calculations. The equation for the log-mean
temperature difference

Prepared By: Engr. M. Akmal Rana Page | 15

 Heat Transfer Operation Lab Manual

Where

T1 = Hot Stream Inlet Temperature

T2 = Hot Stream Outlet Temperature
t1 = Cold Stream Inlet Temperature
t2 = Cold Stream Outlet Temperature

Construction:
They simply consist of two concentric pipes.one fluid flows in inner pipe and other fluid
flows in the annular space between the inner pipe and outer pipe.

Double pipe Heat exchangers can be made with various materials:

 Carbon steel
 Alloy steels
 Copper alloys
 Exotic materials (tantalum).
 Iron
 Aluminum alloys

Prepared By: Engr. M. Akmal Rana Page | 16

 Heat Transfer Operation Lab Manual

Fouling:
Formation of a scale or a deposit on a heat transfer surface is called fouling.
Every single heat exchanger in operation in modern industries is exposed to fouling to
a greater or lesser extent depending on the surface temperature, surface condition
Material of construction, fluid velocity, flow geometry and f lu id composition. The
Fouling phenomenon is time dependent and will result in a decrease in thermal
Effectiveness of a heat exchanger. Once the thermal effectiveness decreases to a
minimum acceptable level, cleaning of the equipment becomes necessary to restore its
performance.
Types of fouling:
 Precipitation fouling ( due to dissolved salts of Ca & Mg )
 Particulate fouling( due to suspended particles )
 Corrosion fouling
 Chemical reaction fouling (due to deposits formed by chemical reactions)
 Bio fouling ( due to the attachment of bio chemical species )
 Solidification fouling ( due to sub cooling of fluids )

Types of heat exchangers:

There are two basic types of heat exchangers.
(1) Indirect contact heat exchanger
Special type of indirect heat exchanger includes the following heat exchanger that are
commonly used in industries.
 Shell and tube heat exchanger

 Double pipe heat exchanger

 Spiral tube heat exchanger
 Plate and frame heat exchanger
 Plate and fin heat exchanger
 Adiabatic wheel heat exchanger
 Phase change heat exchanger
 Pillow plate heat exchanger
(2) Direct contact heat exchanger
Direct contact heat exchanger involves the following types that are used in industry
commonly
 Gas –liquid
 Immiscible liquid-liquid
 Solid –liquid or solid gas

Industrial applications:

Prepared By: Engr. M. Akmal Rana Page | 17

 Heat Transfer Operation Lab Manual

Heat exchangers are widely used in industry both for cooling and heating large scale
industrial processes. The type and size of heat exchanger used can be tailored to suit a
process depending on the type of fluid, its phase, temperature, density, viscosity, pressures,
chemical composition and various other thermodynamic properties.

In many industrial processes there is waste of energy or a heat stream that is being exhausted,
heat exchangers can be used to recover this heat and put it to use by heating a different stream
in the process. This practice saves a lot of money in industry, as the heat supplied to other
streams from the heat exchangers would otherwise come from an external source that is more
expensive and more harmful to the environment.

Heat exchangers are used in many industries, including:

 Waste water treatment

 Wine and beer making
 Refrigeration
 Petroleum refining

In waste water treatment, heat exchangers play a vital role in maintaining optimal
temperatures within anaerobic digester to promote the growth of microbes that remove
pollutants. Common types of heat exchangers used in this application are the double pipe heat
exchanger as well as the plate and frame heat exchanger .Heat exchangers can be used in
food Industry as a process of cooling down various products in the industry. Large number of
products like hazelnut paste and other types of food pastes are required to be cooled down or
heated up in order to be processed further. For this process Heat exchanger can be used.
Ethanol produced from various sources is gaining popularity worldwide for being the next
alternative fuel which will replace the conventional fossil fuels and help in saving the
environment. In the process of ethanol production a network of heat exchangers is used
instead of single or double heat exchangers. The use of heat exchanger networks fulfill the
utilization of waste heat and enable considerable savings of energy in short payback period.

Limitations:

 It is not as cost effective as most shell and tube exchangers

 It requires special gaskets
 Limited volumetric capacity
 Fouling

General Description of Double Pipe Heat Exchanger Equipment

The principal parts are two set of concentric pipes, two connecting Tees, and a return head
and a return bend. The inner pipe is supported within `the outer pipe by packing glands and
the fluids enter the inner pipe proper. The Tees have nozzles or screwed connection attached
to them to permit the entry and exit of the annulus fluid which crosses from one leg to the
other through the return head. The two lengths of the inner pipe are connected by a return
bend which is usually exposed and does not provide effective heat transfer surface. When
arranged in two legs the unit is called hair pin. In case of the double pipe heat exchanger one
fluid flows inside the inner pipe while the second fluid flows in the annular space between the
inner and the outer pipe.

Prepared By: Engr. M. Akmal Rana Page | 18

 Heat Transfer Operation Lab Manual

Procedure

1. Startup

• Fill the steam generator with clean water.

• Switch on steam generating unit until it creates your desired pressure in unit.
• Open cold water inlet
• Measure the flow rate of inlet water

2. Operation
• Open the valve which control flow of steam.
• Inlet temperature of steam can be found from steam table corresponding to steam
pressure
• Note down the inlet temperature of cold water.
• Also note down the outlet temperature of cold water.
• Measure the condensate flow rate.

3. Shutdown

• Shut off the hot stream first

• Close the cold water inet

Observation & Calculation

Hot Water Cold Water Condensate

Sr. Steam Pressure Flow Inlet Outlet Flow Inlet Outlet Flow rate
No (Psi) rate Temp temp Rate Temp Temp (gm / sec)
Kg/sec (T1°C) (T2°C) Kg/sec (t1°C) (t2°C)
1
2
3
4

1. : Amount of heat supplied by steam to the cold water.

Qh = mconde λ + mconde Cp ∆T (Watts)

Prepared By: Engr. M. Akmal Rana Page | 19

 Heat Transfer Operation Lab Manual

2. : Amount of heat taken by cold water.

Qc = m Cp ∆T (Watts)

3. : Heat losses in the system.

Qloss = Qh – Qc (Watts)

4. : Efficiency of the concentric pipe heat exchanger.

Qc
η= * 100
Qh

Safety and Precautions

1. Use PPE i.e. Lab Coat & Safety googles to prevent any harm
2. As we are using steam leather gloves are recommended for operation
3. Do not let Steam to be accumulated in the steam chamber high pressure me cause it to
burst
4. Do not rip the insulation of the exchanger
5. Clean Water must be used to prevent corrosion
6. Learn where the safety and first-aid equipment is located. This includes fire
extinguishers, fire blankets, and eye-wash stations
7. Report any accident immediately
8. In case of fire evacuate the lab immediately

Application
Double pipe heat exchanger found its greatest applications in the industries where the total
heat transfer area is small, 100 to 200 ft2 or less, and is usually use in the refineries,
fertilizers, food, petrochemical industries etc

References
 RC Chemical Engineering by J.M. Coulson & J.F. Richardson 6th Edition (414-416)
 Heat Transfer by J.P, Holman 9th Edition (9-11) & (205-209)
 Process Heat Transfer by D.Q. Kern Indian Edition (25-34)

Prepared By: Engr. M. Akmal Rana Page | 20

 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 5

RADIATION HEAT TRANSFER MODULE

Objective
1. To calculate heat flux through radiation emitted from a metallic plate at different
temperatures.
2. To study how the intensity of radiation varies as the fourth power of the source
temperature.

Theory
 RC Chemical Engineering by J.M. Coulson & J.F. Richardson 6th Edition (438-441)
th
 Heat Transfer by J.P, Holman 9 Edition (12-13) & (367-376)
 Process Heat Transfer by D.Q. Kern Indian Edition (62-68)

General Description of Radiation Heat Transfer Module Equipment

The unit consists of a horizontal track fitted with interchangeable heat radiation source end
and light source. Either the heat radiation detector or the light meter may be placed on the
horizontal track. In addition, a number of accessories can be fitted for experimental purposes.
These include metal plates, two vertically oriented metal plates to form an aperture,
radiometer and a number of light filters. The radiation detectors accessories are all clamped
to stand, which enable them to be positioned at different distances from the source.
Temperatures from plates & output from radiation detector are displayed on digital read out
on the control panel.

Procedure

1. Startup
• Ensure the main switches of the control panel are off.
• Install the heat source assembly on the holder at one end of horizontal track.
• Install radiometer, aperture and plates on horizontal track.
• Connect the heater supply cable to the power output socket of the control panel.
• Ensure the heater cable is connected to panel.
• Initially (When heater is not ON) thermocouple reading from the plate should indicate
ambient temperature.
• Radiometer should indicate approximately zero on the panel.
• Then (After when heater is ON) the thermocouple/radiometer reading should increase.
• Now your equipment is ready for experiment.

2. Operation

Prepared By: Engr. M. Akmal Rana Page | 21

 Heat Transfer Operation Lab Manual

• Follow the basic start-up instructions.

• Connect one of the thermocouple of the target plates on the bench, to record ambient
temperature.
• Position radiometer on the test track at 800mm from the heat source.
• Set the heater temperature to 250oC by heater controller. Monitor T4 reading on the
panel.
• When T4 value has stabilized, move the radiometer to 300mm from heated plate. The
reading of radiometer should start to rise. When the value has stabilized, record T1,
T4, the distance X and radiometer reading, R.
• Repeat the above procedure with an increment of 50˚C from 250˚C to 400˚C.

3. Shutdown
• After performing the experiment turn off the main supply to control panel & also
switch off heater.

Observation & Calculation

Distance between radiometer and heated surface, X =
Temperature of heated surface, T4 (K) =
Temperature of target plate (Ambient), T1(K) =
Heat Flux via Radiation, qb = σ (Ts4 – Ta4)

while σ = 5.6703 10-8 (W/m2K4) - The Stefan-Boltzmann Constant

While, Corrected radiation heat flux, qr = qb× Sin2ɵ

Whereas ɵ can be calculated from the relation;
ℎ
ɵ, in Radians = Tan-1 ( )
𝑥
And corrected radiometer reading, Rc = R× C. Whereas C is average correction factor whose
value can be calculated by using following relationship;
C= ∑ rn / n,
r is the individual correction factor which can be obtained using , r = qr /R
While F is the ratio between actual heat flux through a heated surface to radiations emitted
whose value should remain constant under different temperature conditions.
F = qr/qb
Radiometer Ts Tp
Sr. # Reading , R (˚K) (˚K) Rc
( W/m2 )
qb qr F

Safety and Precautions

Prepared By: Engr. M. Akmal Rana Page | 22

 Heat Transfer Operation Lab Manual

1. High voltages exist so avoid direct skin contact with any live wires .
2. During operation, the heated plate may be heated up to 400 0C and even above. So treat the
unit with caution, as there is a severe burn hazard.
3. Try not to open wooden box during operation, as radiations may damage your skin/eyes.
4. Use gloves & goggles to operate the equipment.
5. Notify the instructor immediately in case of an accident.

Application

Radiation heat transfer module entitles students to operate & understand major heat transfer
mechanism namely radiation which has diverse applications in our industry i.e. Solar panels,
furnaces etc.
References

Prepared By: Engr. M. Akmal Rana Page | 23

 Heat Transfer Operation Lab Manual

EXPERIMENT NO. 6

OPEN PAN EVAPORATOR

Objective
To Study the effect of steam pressure on the economy of the open pan evaporator

Theory
What is evaporation?
Evaporation is a type of vaporization of a liquid that occurs from the surface of a liquid into a
gaseous phase that is not saturated with the evaporating substance. The other type of
vaporization is boiling, which is characterized by bubbles of saturated vapor forming in the
liquid phase.
Water is transferred from the surface to the atmosphere through evaporation, the process by
which water changes from a liquid to a gas. Approximately 80% of all evaporation is from
the oceans, with the remaining 20% coming from inland water and vegetation.
Winds transport the evaporated water around the globe, influencing the humidity of the air
throughout the world. For example, a typical hot and humid summer day in the Midwestern
United States is caused by winds blowing tropical oceanic air northward from the Gulf of
Mexico.

Factors Affecting Evaporation:

Several factors affect the rate of evaporation from surfaces:
1. Energy availability.

Prepared By: Engr. M. Akmal Rana Page | 24

 Heat Transfer Operation Lab Manual

2. Humidity.
3. Rate of turbulent diffusion.
4. Water availability.
Different from drying:
There is usually a difference between two terminologies that are evaporation and drying. The
difference generally stated is between the products of the two operations i.e. the product of
evaporation is liquid or slurry as we are aiming to concentrate a solution. But in case drying,
the moisture content is evaporated from the specimen by the application of heat to the desired
characteristic of the object in solid form. For example, to attain the desired properties of
gypsum, we remove the free moisture content up to 6 remaining molecules of water attached
with it, called inherent moisture content.
Therefore,
Evaporation gives – liquid/slurry
Drying gives – Solid

Types of evaporators:
Types of evaporators are:
1) Natural circulation type
i) Vertical short tube or Calandria evaporator
ii) Long tube vertical (LTV) rising film type
iii) Long tube vertical (LTV) falling film type
2) Forced Circulation type
3) Agitated Film Evaporators
4) Multiple Effect Evaporator
5) Plate Evaporator
6) Open Pan Evaporator

Open pan evaporator:

Pan evaporation is a measurement that combines or integrates the effects of several climate
elements: temperature, humidity, rain fall, drought dispersion, solar radiation, and wind.
Prepared By: Engr. M. Akmal Rana Page | 25
 Heat Transfer Operation Lab Manual

Evaporation is greatest on hot, windy, dry, sunny days; and is greatly reduced when clouds
block the sun and when air is cool, calm, and humid. Pan evaporation measurements enable
farmers and ranchers to understand how much water their crops will need.
An evaporation pan is used to hold water during observations for the determination of the
quantity of evaporation at a given location. Such pans are of varying sizes and shapes, the
most commonly used being circular or square. The best known of the pans are the "Class A"
evaporation pan and the "Sunken Colorado Pan". In Europe, India and South Africa, a
Symon's Pan (or sometimes Symon's Tank) is used. Often the evaporation pans are automated
with water level sensors and a small weather station is located nearby.

General Description of Open Pan Evaporator Equipment

Pan evaporation is a measurement that combines or integrates the effects of several climate
elements: temperature, humidity, rain fall, drought dispersion, solar radiation, and wind.
Evaporation is greatest on hot, windy, dry, sunny days; and is greatly reduced when clouds
block the sun and when air is cool, calm, and humid. Pan evaporation measurements enable
farmers and ranchers to understand how much water their crops will need. An evaporation
pan is used to hold water during observations for the determination of the quantity of
evaporation at a given location. Such pans are of varying sizes and shapes, the most
commonly used being circular or square.

Procedure

1. Startup
• Fill up the open pan with water up to a certain height say 15 cm.
• Set the steam pressure at a certain value say 10 Psi and turn on the equipment.
• Don’t open the steam valve till required pressure is attained.

2. Operation
• Measure the fluid (water) temperature in the open pan evaporator.
• When required steam pressure is attained opened the steam inlet valve in to the
evaporator.
• Measure the temperature of the inlet steam.
• Measure the initial water height.
• After certain time say 10 min measure the water level.
• Calculate the height differences indicating the volume evaporated.
• Measure the condensate (Steam outlet) temperature.

3. Shutdown
• Repeat the experiment following the same procedure for another steam pressure say
20 Psi.
• After performing the experiment turned off the steam.
• Drain all the condensed water and water left over in the evaporator.
• Open safety valve to release all the steam pressure.

Prepared By: Engr. M. Akmal Rana Page | 26

 Heat Transfer Operation Lab Manual

Observation & Calculation

No of Time t Steam Initial Initial Volume of Mass of

observations (Sec) pressure height height water water
p of water of water evaporated evaporated
(Psi) level h1 level h2 kg m=ρ x v
3
(cm) (cm) (cm )

No of Time ( t) Rate of evaporation mass of steam Economy

observations condensed

Economy of the evaporator = mass of water evaporated/mass of steam fed

Safety and Precautions

1. Don’t open the steam valve till the required steam pressure is attained.
2. In case of steam pressure build up open the relief valve.
3. Use gloves to operate the open pan evaporator.
4. Don’t exposed naked skin to hot water or steam as it can cause serious injury.
5. Learn where the safety and first-aid equipment is located. This includes fire extinguishers,
fire blankets, and eye-wash stations.
6. Notify the instructor immediately in case of an accident.
7. If hot surface come into contact with your skin or eyes, flush immediately with copious
amounts of water and consult with your instructor.
Application
1. Pan evaporation is used to estimate the evaporation from lakes.
2. Helps to evaluate the environmental conditions like humidity, wind flow and other
gradients responsible for evaporation.
3. Helps to identify global warming trend and future predictions.
References
 Process Heat Transfer by D.Q. Kern Indian Edition (375-378)
 RC Chemical Engineering Design by R.K. Sinnott 4th Edition (434-437)

Prepared By: Engr. M. Akmal Rana Page | 27

 Heat Transfer Operation Lab Manual

 http://enggyd.blogspot.com/2010/07/calculation-of-steam-consumption-and.html

EXPERIMENT NO. 7

FILM AND DROP-WISE CONDENSATION

Objective
1. To study the effect of cold stream flow rate on the rate of steam condensation.
2. To determine the individual film transfer coefficients in case of smooth and rough
pipe.
3. To compare the experimental and theoretical values of the overall heat transfer
coefficient in the case of
a) Film wise condensation
b) Drop wise condensation
Theory
Condensation of a vapor into a liquid is a process involving large heat transfer coefficients
and a phase change. Condensation takes place when a saturated vapor such as steam comes in
contact with a solid whose surface temperature is below saturation temperature, to form a
liquid phase such as water.
Normally, upon condensation of vapor on a surface such as vertical or horizontal tube or
other surface, a film of condensate is formed on the surface and flows over the surface by the
action of gravity. It is the film of liquid between the vapors and surface that provides main
impedance to the heat transfer. This is called film wise condensation.
Drop wise condensation occurs when a vapor condenses on a surface not wetted by the
condensate. For nonmetal vapors, drop wise condensation gives much higher heat transfer
coefficients than those found with film condensation. For instance, the heat transfer
coefficient for drop wise condensation of steam is around 10 times that for film condensation
at power station condenser pressures and more than 20 times that for film condensation at
atmospheric pressure. However this type of condensation is difficult to maintain at industrial
level accounting to the factors of oxidation, fouling and degradation of coating and eventually
film condensation occurs. Therefore, condensers designs are based on the assumption of film
wise condensation mostly.

General Description of Film and Drop-wise Equipment

The equipment consists of two pipes enclosed in a container. The material of construction for
both pipes is same except the one pipe surface is polished having smooth surface while other
comprise of rough uneven surface. Steam is passed through both pipes and the condensation
phenomena is noticed in the form of layer and droplets on the two surfaces.

Procedure

1. Startup
• Note the room temperature.
Prepared By: Engr. M. Akmal Rana Page | 28
 Heat Transfer Operation Lab Manual

• Open all valves and drain all the water already present.
• Set the apparatus so that the water only flows through rough pipe.

2. Operation
• Open the water flow rate valve and pass it through the rough pipe.
• Open the steam valve and try to set the pressure at a constant value in the chamber.
• Steam condenses in the form of film and condensate is obtained at the bottom.
Measure the mass flow rate and temperature of water (at inlet and outlet) and
condensate.
• Change the cold water flow rate and do same. Take 3 to 4 more readings.
• All the readings should be taken by keeping safety in the mind.
• Measure the condensate (Steam outlet) temperature.
3. Shutdown
• Repeat the experiment following the same procedure for smooth pipe.
• After performing the experiment turned off the steam.
• Drain all the condensed water and water left over in the evaporator.
• Open safety valve to release all the steam pressure.

Observation & Calculation

Flow Steam Tsat -

Tin Tout Tsat Tsurf ∆Tm Condensate Ф U
rate Pressure Tsurf
(degC) (degC) (degC) (degC) (degC) Flow rate (W/m ) (W/m2.K)
2
(LPM) (Psi) (degC)
(gm/min)
0.10 20 31.7 58.2 101.1 81.8 19.3 55.1 45800 831

Graph: Plot graph between flow rate of water and condensate flow rate.
qx = Heater Power (W)
Tsat = Saturation Temperature (K)
Tsurf = Surface Temperature (K)
Ф = Heat Flux (W/m2)
U = Heat Transfer Coefficient (W/m2.K)

Prepared By: Engr. M. Akmal Rana Page | 29

 Heat Transfer Operation Lab Manual

Sample Calculations (For reading number 1)

0.1 Liter 1 Kg 1 min
Min 1 liter 60sec
-3
m = 1.66 × 10 Kg/sec
Q =
= 1.66 × 10-3 Kg/sec x 4186 J/kg.K x (331.2 – 304.7)K
Q = 183.87 Watt

Log mean temperature difference

t1  t2
Tm 
t
ln 1
t2
(Tsat  Tin)  (Tsat  Tout )

(Tsat  Tin)
ln
(Tsat  Tout )
(101.1  31.7)  (101.1  58.2)

(101.1  31.7)
ln
(101.1  58.2)
ΔTm = 55.1 ˚C
Heat flux
qx

d2
 dL 
4
185

3.142(0.0127) 2
3.142  0.0127  0.098 
4
Φ= 45823 W/m2

Heat transfer coefficient, U


U
Tm
45823

55.1
U = 831.6 W/m2.K

Safety and Precautions

1. Never splash water to the control panel. This will cause body injury and damage to the
equipment.
2. Never use your bare hand to test the AC Power Supply. It may cause hazardous injury.
3. Cool down the equipment before draining the water inside the glass vessel so that the
heater will not be overheated when there is no water inside the vessel.
4. Make sure tap water used is free from any contamination to prevent blockage inside the
Prepared By: Engr. M. Akmal Rana Page | 30
 Heat Transfer Operation Lab Manual

condenser.
5. In case of steam pressure build up open the relief valve.
6. Use gloves to operate the film and drop wise condensation unit .
7. Don’t exposed naked skin to hot water or steam as it can cause serious injury.
8. Learn where the safety and first-aid equipment is located. This includes fire extinguishers,
fire blankets, and eye-wash stations.
9. Notify the instructor immediately in case of an accident.
10. If hot surface come into contact with your skin or eyes, flush immediately with copious
amounts of water and consult with your instructor.

Application
Condensation phenomena is used in the designing of condensers being used in heat
exchangers of various designs and come in many sizes, ranging from small units to very large
systems. The use of condensation knowledge helps in designing of pipelines to transport
different chemicals on a large distance from hot sunny to cold climate regions.

References

 http://wins.engr.wisc.edu/teaching/mpfBook/chapter9/node1.html
 Process Heat Transfer by D.Q. Kern Indian Edition (252-256)
th
 Heat Transfer by J.P, Holman 9 Edition (1-9) & (477-482)

Prepared By: Engr. M. Akmal Rana Page | 31

 Heat Transfer Operation Lab Manual

Experiment NO. 8

Gas Geyser

Objective
To determine the thermal efficiency and throughput of gas fired water heater (geyser)

Theory

Water heating is a thermodynamic process that uses an energy source to heat water above its
initial temperature. Typical domestic uses of hot water include cooking, cleaning, bathing,
and space heating. In industry, hot water and water heated to steam have many uses.
Domestically, water is traditionally heated in vessels known as water heaters, kettles,
cauldrons, pots, or coppers. These metal vessels that heat a batch of water do not produce a
continual supply of heated water at a preset temperature. Rarely, hot water occurs naturally,
usually from natural hot springs. The temperature varies based on the consumption rate,
becoming cooler as flow increases.

Construction of a gas fired heater

 Cold Water Supply

Cold water is provided to the tank by a cold water supply line and controlled by a shutoff
valve. It is important to know where the water supply shut off valve is located so
maintenance can be performed on the tank.

 Hot Water Discharge

This is the business end of the hot water heater and the hot water line is what supplies all
your sinks, tubs, showers and appliance needing hot water.

 Construction of the Hot Water Tank

The tank jacket itself is made of steel and encloses a pressure tested water storage tank.
Between the storage tank and the tank jacket is insulation to reduce heat loss of the heated
water. It is a good idea to supplement the insulation by adding a fiberglass insulation tank
jacket to the outside of the hot water heater. These are inexpensive and easy to install.

Inside the tank you will see a dip tube. The dip tube is where the cold water supply enters the
tank to be heated by the gas burner. Since cold air and cold water is denser than hot air or hot
water, the cold water sets at the bottom of the tank until it is warmed by the burner and heated
enough to rise (through convection) to the top of the tank where the hot water hangs out.

In glass-lined tanks there will also be a metal rod in the tank, usually magnesium or

Prepared By: Engr. M. Akmal Rana Page | 32

 Heat Transfer Operation Lab Manual

aluminum) called a sacrificial anode. The anode rod is bolted and fastened to the top of the
tank and extends deep into the tank. Its purpose is to draw corrosion to itself instead of the
metal tank. Some models do not have a separate anode but combine the function of the anode
with the hot outlet. Plastic lines tanks do not have an anode.

 Gas Burner Control Module

The natural gas or propane is supplied by a pipe having its own gas shutoff valve. Just like
you need to know where the water supply shutoff valve is located, you need to know where
the gas line shutoff is located too. The gas line fees into a gas burner control module that
serves as a kind of thermostat for the water heater. It also controls the ignition of the pilot
light.

From the control module we now proceed to the gas burner assembly. This includes the pilot
light and gas burner itself. The pilot light and burner adjustment are key to proper and energy
efficient operation of the water heater. The gas flame should about 1/2 inch in height and
should have blue tips.

 Gas Combustion Exhaust Flue

The exhaust flue serves two purposes. It exhausts combustion gasses from the burner and it
serves as a type of heat exchanger helping to heat the water in the storage tank. The flue must
be properly exhausted to the outside and there are specific code requirements for the type of
flue construction and acceptable details.

 Temperature and Pressure Relief Valve

A safety feature of the hot water heater includes the pressure relief valve and discharge pipe.
It operates like the radiator cap on your car. The purpose of this valve is to relieve excessive
temperature or pressure build up inside the tank if it approaches the limits of the tank's safe
design range. This valve is located on top of the tank and often is threaded directly into the
tank top itself. To test the valve lift up on the handle slightly and hot water should discharge
out of the overflow pipe.

 Tank Drain Valve

The hot water tank can build up sediments in the bottom of the tank if left unmaintained and
by draining the tank using the tank drain valve these sediments cannot build up. And if you
don't have sedimentation then that helps to prolong the life of your tank and improve your
water quality.

Advancements in geyser design

Efficiency of geysers can be improved by increasing the residence time of the flue gases
which increases effective heat transfer’s time as heat transfer is a function of time as well.

Creating turbulence in the flow of fluid in the geyser, as this will break the laminar boundary
layer formation and cause and increase in convective heat transfer co-efficient thus increasing
the efficiency of the heater. This can be done by introducing baffles and fins on the inner pipe
Prepared By: Engr. M. Akmal Rana Page | 33
 Heat Transfer Operation Lab Manual

of the geyser which also increases the heat transfer area.

A material with high thermal conductivity will allow more heat transfer through it so an inner
pipe must be of a material with high thermal conductivity. Analogously and conversely the
outer pipe must have a low thermal conductivity in order to minimize the losses to
surroundings.

Gas fired heaters’ advantages over electrically operated geysers

Since we are dealing with water and there are no circuit boards or electrical components
installed there’s no risk of short circuiting etc. if we experience leakages or other
malfunctioning.

In Pakistan gas is much cheaper than electricity, so a gas fired heater is much viable solution
than an electric heater.

Gas fired heaters won’t work unless they are filled up with water, hence lesser maintenance is
required. Whereas electrically operated ones do not show such features unless proper control
mechanism is applied.

The only con these geysers have is that they are slower than electrically operated ones.

General Description of Instrument

Geysers are similar to double pipe heat exchanger in that the flue gases flow in the inner pipe
and the liquid or water that is to be heated flows in the annular portion of the assembly. For
heating, burner and pilot are installed at the bottom of the assembly. Thermostats are also
installed in the geysers for controlling the temperature of the heating fluid at certain limit. It
is a sort of ON-OFF control system, which shutdown (blow-off) the burner on reaching a
certain temperature level. Where as, the pilot remain in burning condition for again switching
on the burner when temperature decrease from a specified limit due to the entry of fresh
liquid/water. Geysers contain pressure relief valve at the top for maintaining the pressure at
certain level.The mode of heat transfer that is conduction, convection and radiation but the
most dominant mode is by radiation.

Procedure

 Startup
 Fire the geyser
 Set the thermostat
 Note the pressure of gas at the interval during heat up

 Operation
 Heating is continued until the set point of temperature is reached and burner is
switched-off and gas meter reading is noted
 Withdraw the hot water by feeding the cold water of known temperature at
Prepared By: Engr. M. Akmal Rana Page | 34
 Heat Transfer Operation Lab Manual

fixed steady rate (0.06m3) and note the temperature of both hot and cold water
at regular interval(say after every min.).
 Repeat the procedure for second and third set of readings

 Shutdown.
 Turn off the gas connection
 Shut off the water connection
 Put out the flame of geyser

Observations & Calculations

Temperature of cold water supplied = Tcw =

Temperature of hot water supplied = Thw=

Mean pressure of gas supplied = Pg= CV = 1.7 kJ/kg.K

Mean temperature of gas supplied = Tg =

Initial Volume of Gas = V1 =

Final Volume of Gas =V2 =

Volume Of Gas used =Vg = V2 – V1 =

Mass of water withdrawl =Mhw =

Energy (heat supplied) =Qs= Vg * CV * ρg

Energy (heat captured) =Qc=mcw x Cp x (Thw - Tcw)

Thermal efficiency =ŋt =Qc/Qs x 100

Safety and Precautions

1. Do not obstruct air intake

2. Do not obstruct vent hood draft on top of heater
3. Vent pipe gets hot, and must not directly touch other materials including walls and
building materials
4. Gas water heater must have adequate incoming air supply to support proper
combustion and venting
5. The vent goes straight up and out, without any dips
6. Don’t install the geyser on uneven surface.

Application

Prepared By: Engr. M. Akmal Rana Page | 35

 Heat Transfer Operation Lab Manual

Gas fired heater (Geyser) is an excellent equipment for heating water for house hold
purposes. It is frequently used in daily life in winter. It applications include hot water for
washing and cleaning.

Reference

Prepared By: Engr. M. Akmal Rana Page | 36

 Heat Transfer Operation Lab Manual

Experiment NO. 9

Unsteady State Heat Transfer Module

Objective
To study the effect of unsteady state heat transfer on different shapes of objects.

Theory

General Description of Instrument

The unsteady state heat transfer module consist of a tank which has provision of heater in it.
The heater is used to heat the water. A small pump is used to circulate water in this tank. The
flow is controlled by a valve. The flow is read out by a Rotameter. The heater’s temp is
controlled by set point given control panel. This control panel also gives us the temperature
readings of water and the object which is placed in it. Thermocouples are used to measure
temperatures.

Procedure

 Startup
 Plug in the wire of control panel
 Provide the set point to heater.

 Operation
 Install the cylinder in the shape carrier
 Set the circulating pump to a specific speed
 Record the starting condition temperatures and then plunge the shape in the
flow duct
 Measure the temperature of water and objects after 20 s.
 Repeat the procedure for the other object

 Shutdown.
 Turn off the water heater
 Drain the water tank
 Unplug the main switch

Observations & Calculations

Prepared By: Engr. M. Akmal Rana Page | 37

 Heat Transfer Operation Lab Manual

Sr # Time Set Point Water Temp Object Temp

Temp T2 T3
T1

Fo = αt/r2

Bi = hr/k

Prepared By: Engr. M. Akmal Rana Page | 38