EXPERIMENT B3

HEAT LOSSES IN BARE AND LAGGED PIPES AND

FINNED TUBE

INTRODUCTION
Industrial processes usually require steam for operations such as heating. This medium is
usually transported via metal pipes. However, it is inevitable to encounter heat losses in this
arrangement because of the inherent temperature difference existing between the hot pipes
and the surroundings. This can instead be minimized through insulations placed on bare
pipes. On the other hand, if a process requires enhancing heat losses then the use of fins
would be more appropriate. This experiment will involve students in determining the
effectiveness of the apt use of these heat transfer accessories and also quantify necessary
parameters such as the overall effective heat transfer coefficients.

OBJECTIVES
1. To determine the overall effectiveness of industrial insulating materials as compared with
unlagged pipe and finned tube by solving for the lagging efficiency.
2. To compare experimental and theoretical heat losses by conduction, convection, and
radiation from bare and lagged pipes.
3. To measure effective overall heat transfer coefficient of bare and lagged pipes and finned
tubes.

THEORY
A. Bare and Lagged Pipes
When a pipe, bare or lagged, is used to carry saturated steam under pressure, heat will be
lost to the surroundings because of temperature gradient existing between the steam and the
surroundings. The rate of heat transferred naturally will depend on the magnitude of the
temperature difference, the thermal resistance, and the heat transfer area. The most common
method of minimizing heat losses to the surroundings is the use of insulation to increase the
resistance and therefore lower the heat transfer rate. If our purpose is to increase the rate of
heat transfer, we use finned tubes which expose more area per unit length compared to a
similar pipe of the same size.

The rate of heat lost from a pipe carrying steam can be measured simply by determining the
rate of condensation of steam, m, which can be collected at a certain pointerval of time.

By heat balance,

where

Under controlled conditions, the condensed steam can be collected as saturated liquid, thus
Equation (1) simplifies to,

To determine therefore the effectiveness of an insulation, it is just a matter of comparing the
heat lost from the pipe with an insulation with that from a bare pipe. Since heat lost is
proportional to the rate of condensation, and the weight of condensate is proportional to the
volume of condensate v, assuming temperatures and pressures of condensates are the
same, then the lagging efficiency may be determined using the equation
where

To determine the theoretical heat lost, let us consider a pipe of length L insulated as shown
carrying steam at a temperature Th and exposed to surrounding air at Ta and surrounding
walls of the room at Tw.

Before heat is transferred to the surroundings, it travels first from the bulk of the steam
through the steam film condensate, then through the metal pipe, then through the insulation
by conduction until it reaches the surface of the insulation where part of the heat is transferred
to the surrounding air by convection and part by radiation to the surrounding walls. That is,

where hc = Heat transfer coefficient by convection
hr = Heat transfer coefficient by radiation
Ts = Surface temperature of insulation
Ao = Outside area of insulation

For practical purposes, Ta =Tw , therefore Equation (5) becomes

By definition, assuming surrounding area to be large compared to the area of insulation and
gray surfaces, hr is given by

where = Emissivity of surface
T = Absolute temperature

The convection heat transfer coefficient, hc, will depend on the mechanism involved when
heat is transferred from the surface to the air. Under normal conditions, we can consider this
transfer as natural convection since no appreciable movement of air due to mechanical
agitation is encountered. The data of heat transfer from horizontal pipes to air for X from 10^3
to 10^9 is represented by the dimensionless equation,

where

The subscript f indicates that the corresponding property is to be evaluated based on average
film temperature

For air at ordinary temperature and at atmospheric pressure, the simplified dimensional
equation for X from 10^3 to 10^9 may be employed as


where T = Ts - T
Do = Outside temperature of cylinder

The calculation for the simultaneous heat loss by convection and radiation as given by
Equation (6) is straightforward if the surface temperature Ts is known. However, in most
systems this value is not known or cannot be measured with reasonable accuracy. Since Ts is
needed in the evaluation of both hc and hr, then this temperature will have to be evaluated by
trial. Assuming a value of Ts (you may use measured Ts as a guide), hr is evaluated using
Equation (7) and h solved using either Equations (8) or (9). To check the validity of Ts, we use
Equation (4) by expressing this in terms of temperature gradient and resistances, that is

where

Using Equation (10), solve for Ts and compare this with the assumed Ts. Repeat iteration until
close agreement is achieved. With Ts known, calculate the theoretical heat lost using
Equation (6). For bare pipes, trial and error calculation for Ts may be eliminated. Since the
thermal resistance of the metal pipe and the steam film condensate are small, it is safe to
assume that the surface temperature of the pipe is nearly the same as the temperature of the
steam. With Ts known, evaluation of hc, hr and q becomes straightforward. To evaluate the
effective overall heat transfer coefficient from steam to air, we use the equation

which can be compared with the actual or experimental U using the equation


B. Finned Tubes
In this particular experiment, the integral finned tube is made of brass and fabricated by
extruding the fins that are attached to the surface of the tube. The fins are radially extruded
from thin walled tube to a height of 1 mm with 16 fins per inch (25.4 mm). External surface of
the fins is approximately 2 mm wider than the outside surface of the bare tube whose outside
diameter is 16.8 mm. Below is the simplified dimensional figure of the finned tube.


Solve first for the heat transfer coefficient, f h , by assuming that the transfer of heat is by
natural convection.
Hence,

where T = Temperature difference between fin surface and air
Bf = Outside diameter of circular fin

Determine the fin efficiency, , using (P Fig. 10 39). i.e., determine

Compare the fin efficiency, , obtained from (P Fig. 10 39) with the equation

such that

where Bf = Outer diameter of circular fin
Do = Outside diameter of the tube
Sf = Thickness of fin

Compute for the heat losses per foot using the equation

where q ' f = Heat losses per foot
L f = Height of the fin
Tb = Surface temperature of the fin
Ta = Temperature of the air

Then solve for the theoretical heat lost using the equation

where q = Theoretical heat lost
L = Total length of the tube, ft














EQUIPMENT

A. Actual Equipment













B. Schematic Diagram of the Equipment







C. Description of the Equipment

The equipment set-up consists of the following: six graduated cylinders of 5500 to 5000 ml
capacity; one stopwatch; six beakers of 1000 to 3000 ml capacity; two pairs of asbestos
gloves; pair of pliers; 10 mercury thermometers; a digital surface thermometer; a meter stick;
and compressed air supply line.

The test equipment consists of a pipe insulated with asbestos (Pipe A), a bare pipe coated
with silver paint (Pipe B), a bare pipe coated with black paint (Pipe C), a GI pipe without any
insulation or coating (Pipe D), a finned tube (Pipe E), and a pipe insulated with styrofoam
(Pipe F).

These pipes, which are slightly inclined, are rigidly connected to a large horizontal and
properly insulated pipe which in turn is connected to an insulated steam supply line leading to
the steam boiler. In the supply line, there is a pressure gage that indicates the pressure of the
steam coming from the boiler. The pressure within the test pipes is indicated by another gage
that is located just after the manually controlled valve. Each pipe is equipped with three
thermometer wells that are used to approximately determine the surface temperature by
means of a mercury thermometer. The digital surface thermometer may be used to verify
these readings. Located at the side of the supply line is a set of throttling calorimeter which
can be used to determine the quality of steam entering the distribution tube.

On the other side, the end of these pipes are connected to an insulated cylindrical
condensate collector provided with a stopcock on top, a sight glass at the sides with valves,
and a control valve at the discharge pipe connected at the bottom of this collector. The
discharge pipe goes inside a column in a form of a U-tube. The exit pipe can be turned
forward for collecting the condensate or sideward for draining the condensate. The cylindrical
coolers are provided each with cooling system in parallel where cooling water can be
controlled by a valve located at the main water supply line. The used cooling water from these
coolers is discharged directly to the drain. See Figures 2 and 3 for the equipment set up.



PROCEDURE

1. Preheating. Before starting a run, it is necessary to preheat the tubes to a temperature as
near as possible to the prescribed temperature for the run. This is achieved by partly opening
all the condensate discharge valves and allowing the steam to pass through the tubes by
opening the steam pressure control valve to maintain approximately the same pressure as
that to be used for the particular run. This procedure will also remove noncondensable gases
inside the tubes. Perform this operation for about 5 minutes. During this period, you may
check the temperature recorded by the thermometers placed on each well to determine
whether the system has already stabilized.
Note: To avoid burns always wear asbestos gloves when handling hot metallic parts.

2. Start of Run. Before starting a timed run, make sure that the condensate collector is
empty. To check, open fully the valves on top and bottom of the sight glass. If water is
indicated, this can be removed by fully opening the discharge valve. To start the timed run all
the six discharge valves are closed simultaneously if possible. It is important that somebody
must be stationed to control the steam supply valve to watch the pressure gauge since
closing the discharge valves might suddenly raise the steam pressure inside the pipes to a
dangerous level. It is recommended that the supply valve be partly closed while the
discharged valves are being closed. At this point start the time and adjust the control valve to
maintain the desired pressure constant throughout the run.

3. Timed Run

a. Method I. This timed run should last not less than 25 minutes. Get temperature readings
from time to time from the thermometers from each well, or by using the digital thermometer.
If the condensate collector is about to be filled up as indicated in the sight glass, collect some
of the condensate using a beaker by carefully opening the discharge valve just to allow part of
the condensate out. Do not discharge completely the condensate or steam will escape. If
there are leaks encountered, collect these to be added later to the condensate collected from
each pipe. When collecting condensate, make sure that the cooling system is on.


b. Method II. After closing all the discharged valves simultaneously, if possible, adjust the
steam valve to a certain pressure and maintain it constant throughout the timed run. Open the
valve at the main water supply line for the cooling water. Allow the condensate to reach a
certain level as indicated in the sight glass. Mark this level and start timing the run. Open the
discharge valve to collect some of the condensate from the collector in a beaker. The level of
the condensate may rise or fall during the run but adjust the discharged valve so that the level
of the condensate will not be far from the marked level.

4. End of Run

a. Method I. When the prescribed time is reached, close completely the steam supply valve
then open slowly one, two or three stopcocks on top of the condensate collector to remove
the residual steam inside the pipes. Be careful when opening these valves, bear in mind that
the steam is initially at high pressure. When the pressure in the pipes reaches atmospheric,
collect the condensate in a beaker or graduated cylinder one at a time or simultaneously.
Draining will not remove all the condensate because some will stay inside the U-tube within
the cooler. One way of removing the condensate completely is to use compressed air. First,
close the stopcocks and connect the compressed air line to one of the stopcocks. Adjust the
air regulator to indicate an air pressure of about 55 psig. Then slowly open the stopcock to
allow air to enter the collector. Because of the pressure, residual condensate will be driven
out from the U-tube. Combine the condensate collected from each pipe and record the
volume.

b. Method II. The steam supply valve is closed completely at the end of the timed run. But a
few minutes before closing the supply valve, let the condensate level be higher than the
marked level in step 3 by partly closing the discharge valve. Then right after closing the steam
supply valve, slowly drain the condensate and stop draining when the level is on the mark.

Note: To start another run, repeat the procedure by first preheating the systems at least three
runs must be performed. The recommended pressures are 15, 20, 25 psig, although you can
choose the pressure you want as long as it does not exceed 60 psig. To determine the quality
of steam, use the throttling calorimeter provided near the set up.

DATA






RUN 1 RUN 2
TIME Pipe #1 (C) Pipe #2 (C) Pipe #3 (C) TIME Pipe #1 (C) Pipe #2 (C) Pipe #3 (C)
0
33 88 88
0
38 98 99
5
38 115 112
5
39 120 116
10
37.5 111 110
10
39 119 118.5
15
38 115.8 113.7
15
39 120 118
20
38.3 115.8 112
20
39.5 121 118
25
38 112 109.5
25
40 125 121
30
38 117 114
30
40 121 118
MID SECTION
RUN 1
TIME Pipe #1 (C) Pipe #2 (C) Pipe #3 (C) Pipe #4 (C) Pipe #5 (C) Pipe #6 (C)
0 38 90 90 56 72 34
5 38 112 110 106 90 36
10 39 106 108 104 92 38
15 39 114 108 108 94 38
20 39 114 110 108 94 38
25 39 111 109 105 92 38
30 39 112 112 110 94 38
MID SECTION
RUN 2
TIME Pipe #1 (C) Pipe #2 (C) Pipe #3 (C) Pipe #4 (C) Pipe #5 (C) Pipe #6 (C)
0 38 90 90 94 94 38
5 38 112 110 111 94 37
10 39 106 108 112 95 3
15 39 114 108 112 96 38
20 39 114 110 113 97 38
25 39 111 109 116 98 38
30 39 112 112 38 38 38
ANALYSES AND CALCULATIONS

Bare and Lagged Pipes

1. Using the bare pipe (without any coating) as the reference, determine the lagging efficiency
of each insulation for each run. Explain.

=
(

Where:
V
b
= volume of condensate collected for bare pipe
V
l
= volume of condensate collected for lagged or insulated pipe.


Table 1. Lagging efficiency for pipes in the first run
Pipe A B C D E F
Condensate
Volume (ml)
298 642 790 720 480 240
Lagging Efficiency 0.58611111 0.10833 -0.0972 0 0.33333 0.66667

Table 2. Lagging efficiency for pipes in the second run
Pipe A B C D E F
Condensate Volume
(ml)
422 616 942 845 555 390
Lagging Efficiency 0.50059172 0.27101 -0.1148 0 0.3432 0.53846

Based from the data, the pipe insulated with Styrofoam/polystyrene (Pipe D) gives the highest
lagging efficiency. Pipe A insulated with asbestos also shows a high lagging efficiency for both
runs.

2. Is there a trend in terms of the pressure of steam and the amount of condensate collected?
Plot values to support your explanation.


Table 3. Amount of condensate collected for each pipe at different steam pressure










From the graph, the majority of the pipes show a directly proportional relationship between
the steam pressure and the amount of condensate collected. Excluding Pipe B (which shows
a rather inverse relationship), it can be attributed to the fact that at a higher pressure, the
steam supply to the experimental equipment also increases, which also results to a higher
volume of condensable steam.

3. Calculate the theoretical heat lost from each pipe and the surface temperature of the pipe
for each run. Compare these with experimental values. Determine the percentage difference.
Explain your findings.

q = (h
c
+ h
r
)A
o
(T
s
T
a
)


0
200
400
600
800
1000
0 10 20 30 40
C
o
n
d
e
n
s
a
t
e

v
o
l
u
m
e

(
m
L
)

Pressure (psi)
Pressure vs. Condensate volume
Pipe A
Pipe B
Pipe C
Pipe D
Pipe E
Pipe F
Pipe A Pipe B Pipe C
Pressure Volume Pressure Volume Pressure Volume
20 298 20 642 20 790
30 422 30 616 30 942
Pipe D Pipe E Pipe F
Pressure Volume Pressure Volume Pressure Volume
20 720 20 480 20 240
30 845 30 555 30 390

Table 4. Experimental and theoretical heat losses for pipes for run 1








Table5. Experimental and theoretical heat losses for pipes for run 2

Pipe A Pipe B Pipe C Pipe D Pipe E Pipe F
Heat loss
(experimental)
490.64 716.2 1095.22 982.45 645.28 453.44
Heat loss
(theoretical)
495.98 965.54 1320.72 972.48 737.41 410.07
% difference 1.08 25.82 17.07 1.02 12.49 10.58

From tables 4 and 5, the differences in values can be attributed to either errors in part of the
experimenters in performing the experiment, the conditions of the environment and their
impact with the surface temperature readings and also with the heat losses induced by the
friction within the pipes as the steam travels through the line.

4. Based on the actual heat lost measured, determine the effective overall heat transfer
coefficients for all the pipes.

0
=

)(1800 )












Pipe A Pipe B Pipe C Pipe D Pipe E Pipe F
Heat loss
(experimental)
384.82 829.05 1020.17 929.77 619.85 309.92
Heat loss
(theoretical)
364.89 787.25 1206.94 930.2 660.25 410.07
% difference 5.46 5.34 15.47 0.056 6.12 24.42

Table6. Experimental overall heat transfer coefficient for each pipe for run number 1

Pipe A Pipe B Pipe C Pipe D Pipe E Pipe F
Condensate
volume (mL)
298 642 790 720 480 240
ms
664393.98

1431345


1761313

1605247 1070165 535082
Uo
(experimental)
15.0153 81.2562 99.9882 91.1258 54.2893 12.0929


Table7. Experimental overall heat transfer coefficient for each pipe for run number 2

Pipe A Pipe B Pipe C Pipe D Pipe E Pipe F
Condensate
volume (mL)
422 616 942 845 555 390
ms

942359.76


1375577


2103561

1886953 1239359 870901.2
Uo
(experimental)
15.0153 81.2562 99.9882 91.1258 54.2893 12.0929


From tables 6 and 7, pipes which are insulated have the lowest values for Uo. In principle, the
lower the value for the over-all heat transfer coefficient, the better the performance of an
insulator in avoiding heat losses.


Conclusion:

It can be concluded that in determining the lagging or insulating efficiency, the thermal
conductivities of the insulating material are very important. On the other hand, the determined
experimental and theoretical heat losses for each pipes shows reasonably same results
through the use of the heat transfer coefficient for convection and radiation in computing for
heat losses.
REFERENCE:
Ronderf C. Bolo and Servillano Olano, Jr., Spreadsheet Calculations for Unit Operations
Laboratory Experiments Proceedings of the 2002 Chemical Engineering Congress, De
La Salle University, December, 2002