ME322 Mechanical Lab 1 (Long report 2)

Forced convection
College of Engineering , Mechanical Engineering Department,
King Saud University
GROUP (3)
SULAIMAN ALKHULAYFI – 439100967
ABDALRHMAN ALSUHAIM – 439100966
KHALED ALHELAL – 439101070
YOUSIF ALKHOLIFI – 439101073
SULTAN ALMUTAIRI– 439101952

Section number : 46377

DATE OF WRITING
1443/9/22
2022/4/23
Summary:

Experiment has been done to study experimentally the convection heat transfer coefficient and
Nusselt number of a flow inside an insulated pipe. Also, analytically measuring both the
convection heat transfer coefficient and Nusselt number & comparing it to the experimental
results. And finally calculating the thermal losses percentage through lagging.
The experiment was conducted through a set up containing 14 different thermocouples placed
inside and outside the pipe to measure temperatures, also a fan to blow the air inside the pipe,
From the results found, the analytical convection heat transfer coefficient is larger than the
experimental with about 20% difference, and for the Nusselt number the analytical result is
larger than the experimental with about 20.1%.

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Table of contents:

Summary:....................................................................................................................................................1
Table of contents:.......................................................................................................................................2
List of figures and tables:............................................................................................................................3
Nomenclature:............................................................................................................................................4
Introduction:...............................................................................................................................................5
Objectives:..................................................................................................................................................5
Theory:........................................................................................................................................................6
Methodology:.............................................................................................................................................8
Results.......................................................................................................................................................10
Table of Measurements:..........................................................................................................................10
Discussion:................................................................................................................................................14
Conclusion:................................................................................................................................................15
References:...............................................................................................................................................15

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List of figures and tables:

Figure 1 Boundary layers development on a heated vertical plate.............................................................5

Figure 2 Boundary layers development in convection heat transfer...........................................................5
Figure 3 Types of flow modes......................................................................................................................6
Figure 4 Experimental device......................................................................................................................8
Figure 6 flow path and more detailed about device....................................................................................9
Figure 5 pipe cross-section configuration...................................................................................................9

Table 1 Experiment results........................................................................................................................10

Table 2 Experimental results.....................................................................................................................11

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Nomenclature:

'
ℜ=Rylon d s number

ρ=Fluid density
( )
kg
m3

V =Fluid velocity ( ms )
D= pipe diameter ( m ) μ=dynamic viscosity ( )
Ns
m
2

Nu=Nusslet number
Pr=Prantl number

Cp=spisifc heat ( kgJk ¿ ¿)

W
K f =Thermal conductivity( )
mK
St =Stanton number

h=convection heat transfer coefficient

( )
W
2
m K

∆ T f =T outlet −T inlet of the fluid ( C° )

V =volt of heat source(Volt )
I =current of heat source ( ampere )

q̈=heat flux
( Wm )
2

L=length of pipe ( m )
W
K ins =thermal conductivity of the insulator ( )
mK

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 Introduction:

Heat is the transfer of energy by interactions of a system with its surroundings. The nature of
these interactions can be of three modes Conduction, Convection and Radiation, the focus will be
towards the convection mode of heat transfer. Basically convection is the heat transfer between a
fluid in motion and a surface due to the temperature differences between the two. Convection is
related to fluid flow over a surface and development of velocity and thermal boundary layers
(fig.1) . Heat is transferred by convection with two mechanisms, one is diffusion or the random
motion of molecules, the other mechanism is bulk or macroscopic motion of the fluid.
Convection in general has two types forced convection, and free (or natural) convection. Forced
convection is when fluid moves due to applied external force. Free convection is when fluid
moves due to internal force (buoyancy force) (fig.2). Our focus will be on forced convection.
Forced convection can be external or internal. External forced convection is when the boundary
layers develop freely without external constraints. Internal forced convection is when the
boundary layers development is constrained by the surface (such as pipe, duct, etc.). In this
experiment the flow is internal.

Figure 2 Boundary layers development in convection heat transfer Figure 1 Boundary layers development on a heated vertical plate

Objectives:

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  Experimentally measuring the convection heat transfer coefficient & Nusselt number .
 Analytically measuring both the convection heat transfer coefficient and Nusselt number
& comparing it to the experiment results.
 Calculating the thermal losses percentage through lagging

Theory:

Reynolds number:
Which is number used to determine the state of flow
ρVD
ℜ=
μ
 ρ is the fluid density.
 V is the fluid velocity.
 D is the pipe diameter.
 μ is the dynamic viscosity.

Forced convection:
There are two flow conditions for forced convection to occur
fig 3:
 Laminar flow: when (ℜ< 2100)
 Turbulent flow: when (ℜ> 4000)
 Transition flow: when ( 2100< ℜ<4000 )
The flow will be vary depending on the viscosity and velocity
of the fluid. Laminar flow happens at lower Reynolds number
ℜ and viscous forces is dominant. Turbulent flow happens at Figure 3 Types of flow modes
higher Reynolds number ℜ and inertia forces is dominant.
Dittus –Boelter correlation:
Dittus –Boelter correlation is used to find the Nusselt number Nu in fully developed region
(turbulent flow) for circular tube.
Nu=0.023 ℜ× 0.8(Pr)×n
μ Cp
 Pr is the Prandtil number ¿
K
 Cp is specific heat
 K is the thermal conductivity of the fluid.

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Stanton number St
 Which is dimensionless number measuring the ratio of heat transferred into the fluid
thermal capacity.

St =
Nu
=
hD
K
=
h( )

( )( )
ℜ× Pr ρV μCp ρ× V × C p
×
μ K

Convection heat transfer coefficient h theoretical method

Convection heat transfer coefficient h we can find it by using Nusselt number Nu in the
following relation:
hD Nu× K
Nu= → h=
K D

Convection heat transfer coefficient h experimental method

[ q gained bythe fluid=q supplied by electrical coil−q lost by the instulation ]

q supplied by electricalcoil =V× I ,

 V is voltage
 I is current
q gained bythe fluid =h × A × ∆ T f = ṁ×Cp × ∆ T , A = πdL,

 ṁ is mass flow rate,

 ∆ T f =T outlet −T inlet which is the different temperature between outlet and inlet of the pipe.
 ∆ T is temperature difference between the heater and fluid.
2 π × L × K ins × ∆ T i
q lost by the instulation=
ln ⁡ ( )
Di
Di
out

 K ins thermal conductivity of the insulator

 D i , D i are inner and outer diameter of the insulator
¿ out

 L is the length of the pipe

 ∆ T i=T i −T i which T i is inner temperature surface of insulator and T i is outer
¿ out ¿ out

temperature surface of insulator

q gained by the fluid
After finding the q gained by the fluid we will find q̈=
A
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Then we use the following formula q̈=h × ∆ T f
q̈
So h=
∆Tf

Methodology:

Experimental set up
Figure 4 Experimental device

A. Fan unit: used to supply air into the pipe.

B. Air flow control valve: used to control the quantity of air flows through the pipe.
C. Air inlet thermometer: used to find the inlet temperature of air flows through the copper
pipe.
D. Manometer: used to find the pressure drop across the orifice meter (orifice meter used to
measure the flowrate of the air).
E. Voltmeter: used to find the value of the current supplied for heating pipe.
F. Ammeter: used to measure the current supplied to the heating coil.

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 G. Temperature display unit: used to display the temperature at different point of the pipe.
H. Temperature selector switch: used to find the temperature at any point inside or outside
the pipe.

Experimental procedure

figure1 shows the different temperature point which indicated to be 14 points distributed throughout
the pipe and insulator. We will turn on the device and measure the temperature at indicated points.

Figure 2 shows the insulation thickness and internal diameter of the pipe

Figure 5 pipe cross-section configuration Figure 6 flow path and more detailed about device

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Results:

Patm =70 . 8 cmHg , Porf =44 mm H 2 O , P fan =214 mm H 2 O , Plength=61 mm H 2 O

Di =34 . 4 mm , Di =73 mm
¿ out

Properties of air are calculated at 300 K

Table of Measurements:

Table 1 Experiment results

Laboratory Atmospheric Pressure kPa 94.459
Conditions Ambient Temperature C 17
Test Number x 1
Orifice Pressure Drop Pa 375.527
Flow Conditions Fan Preesure Pa 1826.426
Test Length Pressure Drop Pa 520.617
Inlet Temperature C 26
Voltage Volt 110
Electrical Heater
Current Ampere 2.1
Outer Surface of Tube: T1 C 42.5
Outer Surface of Tube: T2 C 50.3
Outer Surface of Tube: T3 C 52.4
Outer Surface of Tube: T4 C 54.2
Outer Surface of Tube: T5 C 54.8
Outer Surface of Tube: T6 C 52.1
Outer Surface of Tube: T7 C 51.5
Thermocouples
Inner Surface Insulation: T8 C 33.1
Inner Surface Insulation: T10 C 72.5
Inner Surface Insulation: T12 C 83.9
Outer Surface Insulation: T9 C 25
Outer Surface Insulation: T11 C 40.1
Outer Surface Insulation: T13 C 42.4
Transverse Centreline: T14 C 39.3

Table 2 Experimental results

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 Air Density ρ kg/m3 1.181
Air Viscosty v Pa.s 1.557E-05
Air Thermal Conductivity kf W/m.K 0.02617
From Tables
Air Thermal Capacitance Cp J/kg.K 1005.693
Insulation Thermal Conductivity kins W/m.K 0.04
Copper Thermal Conductivity kCu W/m.K 340
Flow Condition Test Number x - 1
Heated Pipe Length L m 1.685
Inner Pipe Diameter Dpipe m 0.032
Pipe Cross-Section Area A pipe m2 0.000804
Orifi ce Wider Diamater D1 m 0.04
Geometrical Data Orifi ce Narrow Diamater D2 m 0.076
Orifice Wider Area A1 m 2
0.004538
Orifice Narrow Area A2 m 2
0.001257
Pipe Surface Area As m 2
0.169
Orifice Coffi cient of Discharge Cd xxxxx 0.613
Air Average Velocity V m/s 25.145
Operating
Air Mass Flowrate m' kg/s 0.024
Conditions
Averaged Pipe-Surface Temp Ts C 51.114
Heat Generated by Heater qgen W 231
Heat Lost Through Lagging qloss W 15.384
Heat Available for Air to Gain qgain W 215.616
Heat Actually Gain by Air qactual W 216.1713
From Experimental
Thermal Losses Percentage %Them % 6.660
Measurements
Heat Flux q'' W/m 2 1272.86
Experimental Convection Coff hexp W/m2.K 77.143
Experimental Nusselt Number Nuexp xxxxx 94.319
Experimental Stanton Number Stexp xxxxx 0.002583
Reynolds Number Re xxxxx 5.166E+04
Prandtl Nuumber Pr xxxxx 0.708
Analytical Analytical Nusselt Number Nuana xxxxx 118.110
Analytical Nusselt Number Stana xxxxx 0.003229
Analytical Nusselt Number hana W/m .K2 96.601
Error in Nusselt Number %dNu % 20.142
Error Error in Stanton Number %dSt % 20.006
Error in Convec Coff Number %dh % 20.142

1- Experimental Calculation:
 Average Air Velocity:

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 √
2∗∆ P
ρ air A 2 C d

[ ( )]
2
A2
ρair∗ 1 −
A1
V= →V =25.145 m/s
ρair A pipe
 Average Air Mass Flowrate:
kg
ṁ=ρ air V A pipe=1.181∗25.145∗0.000804 → ṁ=0.024
s
 Inner Surface Average Temperature of Pipe:
T 1+T 2 +T 3 +T 4 +T 5 +T 6+ T 7
T s= → T s=51.114 ℃
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 Heat Generated by Heater:
q gen=I∗V =2.1∗110→ q gen=231 W
 Inner Surface Average Temperature of Insulator:

T 8 +T 10 +T 12
Ti = →T i =63.167 ℃
¿
3 ¿

 Outer Surface Average Temperature of Insulator:

T 9 +T 11+T 13
Ti = →T i =35.833 ℃
out
3 out

 Heat Lost Through Lagging:

2 π∗k ins∗L∗(T i −T i )
q loss= →q loss=15.384 W
¿ out

Di
ln ⁡( ) out

Di ¿

 Heat Available for Air to Gain:

q gain =q gen−q loss=231−15.384 →q gain =215.616 W

 Since there is no thermocouple to measure the temperature of the outlet air; we assume
that the actual heat gain by the air is the same as the heat available for air to gain.
 Thermal Losses Percentage:
q loss 15.384
%Them= ∗100= ∗100 % → %Them=6.66 %
q gen 231

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 Heat Flux:
q gain 215.616 2
q̈= = → q̈=1272.86W /m
As 0.169

 Experimental Convection Coefficient:

q̈ 1272.86 2
hexp = = → hexp =77.143W /m . K
T 1−T ¿ 42.5−26

 Experimental Nusselt Number:

hexp∗D pipe 77.143∗0.032
Nu exp= = → Nu exp =94.319
kf 0.02617

 Experimental Stanton Number:

hexp 77.143
St exp = = → St exp =0.002583
ρ air∗V∗C p 1.181∗25.145∗1005.693

2-Analytical Calculations:

 Reynolds Number:
V ∗D pipe 25.145∗0.032
ℜ= = → ℜ=5.166 ×104 (T urbulant )
v 1.557 × 10
−5

 Prandtl Number:
From table: Pr=0.708
 Analytical Nusselt Number:
4 0.8
Nu ana =0.023∗ℜ ∗Pr =0.023∗( 5.166 ×10 ) ∗0.708 → Nu ana=118.110
0.8 0.4 0.4

 Analytical Convection Coefficient:

Nuana∗k f 118.11∗0.02617 2
h ana= = →h ana =96.601W /m . K
D pipe 0.032
 Analytical Stanton Number:

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 Nu ana 118.11
St ana = = → St ana =0.00323
ℜ∗Pr ( 5.166 ×10 4 )∗0.708
3- Error Prediction:
Nuana −Nuexp 118.11−94.319
% ∆ Nu= ∗100= ∗100 →% ∆ Nu=20.142 %
Nuana 118.11

Discussion:

From this experiment Convection Heat Transfer Coefficient has been calculated using both the
experimental & analytical method. Before that some parameters in which the former depends on
are measured. Such like temperatures at different locations, average air mass flowrate & velocity,
pressure drop along the test section & electrical power. Consequently, the convection coefficient
has been calculated & it has been noticed some difference between the experimental & analytical
values.

Firstly, the temperatures have been measured using Thermocouples (fig 6) at different locations
for the pipe & the insulation Table 1 & 2, unfortunately due to some limitation in the lab set-up
the outlet temperature of the air is not measured, some assumptions have been to calculate the
energy gain by the air. The pressure drop is measured using a manometer. Furthermore, the
average mass flowrate is measured using an Orifice Meter ( which happen to be 0.024 kg/s ) in
which is used to calculate average velocity in the pipe ( 25.145 m/s ). In addition, the electrical
power is measured using the displayed voltage & current.

Secondly, the heat generated by heater & losses through lagging are calculated (fig 5) , which
resulted to 6.66 % loss of thermal energy. Heat flux is calculated using the actual heat gained by
the air divided by the pipe surface area. Consequently, the convection coefficient is calculated by
assuming that the heat flux is constant along the pipe in which results to a constant temperature
difference between the fluid & the pipe surface at every section, The Experimental Convection
Coefficient is calculated to be 77.143 .

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Furthermore, The Experimental Nusselt Number is calculated to be 94.319 .In addition, The
Analytical Convection Coefficient is calculated using empirical correlations ( which happen to
be 96.601), resulting to 20.142% difference between the experimental & analytical value.

Finally, the difference in values can be due to some limitations in the set-up like insufficient
insulation, no thermocouples for measuring the air & inner surface of the pipe temperatures at
the same location. In addition, miscellaneous heat losses & human errors like taking wrong
readings.

Conclusion:

We measure temperature and heat flux to find h (Table 1 & 2), while h effects on heat transfer by
forced convection like flow movement and randomly flow rate. Then we tried to compere
between Nu (experimentally) and Nu (Analytically), and we have error arrive to 20%.
which mean difficulty of calculating heat transferring the case of heat transfer by forced
convection.

References:

 www.cfdsupport.com

 Heat Tranfer . J. P. Holman. 7th Edition. McGrawHill Publishing.

 Thermodynamics: An Engineering Approach. Yunus A. Cangel and Micheal A. Boles. 4th

Edition. ISBN-10: 0072383321.

 TD1 Forced Convection Heat Transfer User Guide. TecQuipment Ltd. 2008

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