MAPÚA UNIVERSITY

Muralla St. Intramuros, Manila

School of Mechanical and Manufacturing Engineering

EXPERIMENT NO. 7
HEAT LOSSES

12 MAHMUD, Ali R. Date of Performance: September 28, 2018

2015151413 Date of Submission: October 12, 2018
ME144L – A1
Group No. 2

GRADE

Engr. TeoduloA. Valle

Instructor
 TABLE OF CONTENTS

Objectives Page 1

Theory and Principle Page 1

List Of Apparatus Page 6

Procedure Page 7

Set-up of Apparatus Page 8

Final Data Sheet Page 15

Sample Computations Page 16

Discussion of Result Page 16

Questions and Answers Page 17

Conclusion Page 20

Reference Page 21

Preliminary Data Sheet Page 22

 i
OBJECTIVES
To determine the efficiency of the insulation using steam as the heating medium for

a) Partly covered and

b) Fully covered pipes

THEORY AND PRINCIPLE

Heat is the form of energy that flows from body at high temperature to the body at low
temperature. There are three modes of heat transfer: conduction, convection and radiation. Some
media is required for transfer of by conduction and convection, but for radiation no media is
required. Heat transfer is the process of transfer of heat from high temperature reservoir to low
temperature reservoir. In terms of the thermodynamic system, heat transfer is the movement of
heat across the boundary of the system due to temperature difference between the system and the
surroundings. The heat transfer can also take place within the system due to temperature
difference at various points inside the system. The difference in temperature is considered to be
‘potential’ that causes the flow of heat and the heat itself is called as flux.

Fig.1. Mechanisms of Heat Transfer

Conduction is the transfer of heat between substances that are in direct contact with each
other. The better the conductor, the more rapidly heat will be transferred. Metal is a good
conduction of heat. Conduction occurs when a substance is heated, particles will gain more
energy, and vibrate more. These molecules then bump into nearby particles and transfer some of
their energy to them. This then continues and passes the energy from the hot end down to the
colder end of the substance. In pipes, the amount of heat that flows from radial direction is:

𝑇2 − 𝑇1 𝑇2 − 𝑇1 Equation 1
𝑄= 𝑟 = 𝑑
ln( 2 ) ln( 2 )
𝑟1 𝑑1
2𝜋𝑘𝐿 2𝜋𝑘𝐿
Where:

𝑘 = 𝑡ℎ𝑒𝑟𝑚𝑎𝑙 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦

𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑖𝑝𝑒

Fig.2. Heat Transfer through a single pipe

Fig.3. Heat Transfer through composite pipe

𝑄 = ∆𝑇/𝑅𝑇 Equation 2

Where:

𝑅𝑇 = 𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒

4
 𝑟 𝑟 Equation 3
1 ln (𝑟2 ) ln (𝑟3 ) 1
1 2
𝑅𝑇 = + + +
𝐴𝑖 ℎ𝑖 2𝜋𝐿𝑘1 2𝜋𝐿𝑘2 𝐴𝑜 ℎ𝑜

Where:

ℎ𝑖 = 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑙𝑚 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑎𝑛𝑐𝑒 𝑜𝑛 ℎ𝑜𝑡 𝑠𝑖𝑑𝑒

ℎ𝑜 = 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑙𝑚 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑎𝑛𝑐𝑒 𝑜𝑛 𝑐𝑜𝑙𝑑 𝑠𝑖𝑑𝑒

Convection is heat transfer by mass motion of a fluid such as air or water when the
heated fluid is caused to move away from the source of heat, carrying energy with it. Convection
above a hot surface occurs because hot air expands, becomes less dense, and rises (see Ideal Gas
Law). Hot water is likewise less dense than cold water and rises, causing convection currents
which transport energy. Convection can also lead to circulation in a liquid, as in the heating of a
pot of water over a flame. Heated water expands and becomes more buoyant. Cooler, denser
water near the surface descends and patterns of circulation can be formed, though they will not
be. Heat by convection heat transfer can be calculated using the formulae:

If the specific heat is known:

𝑄 = 𝑚𝑐𝑝 ∆𝑇 Equation 4

If the convection is surface convection:

𝑄 = ℎ𝑐 𝐴∆𝑇 Equation 5

Where:

ℎ𝑐 = 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑎𝑠𝑠𝑜𝑐𝑖𝑎𝑡𝑒𝑑 𝑤𝑖𝑡ℎ 𝑐𝑜𝑛𝑣𝑒𝑐𝑡𝑖𝑜𝑛

Fig.4. Convection Heat Transfer

5
 Heat transfer through radiation takes place in form of electromagnetic waves mainly in
the infrared region. Radiation emitted by a body is a consequence of thermal agitation of its
composing molecules. Radiation heat transfer can be described by reference to the “black body”.
The black body is defined as a body that absorbs all radiation that falls on its surface. Actual
black bodies don't exist in nature - though its characteristics are approximated by a hole in a box
filled with highly absorptive material. The emission spectrum of such a black body was first fully
described by Max Planck. A black body is a hypothetical body that completely absorbs all
wavelengths of thermal radiation incident on it. Such bodies do not reflect light, and therefore
appear black if their temperatures are low enough so as not to be self-luminous. All black bodies
heated to a given temperature emit thermal radiation.The radiation energy per unit time from
a black body is proportional to the fourth power of the absolute temperature and can be
expressed with Stefan-Boltzmann Law as:

𝑄 = 𝑒𝜎𝐴(𝑇14 − 𝑇24 ) Equation 6

Where:

𝑒 = 𝑒𝑚𝑚𝑖𝑠𝑖𝑣𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟

𝑊
𝜎 = 𝑆𝑡𝑒𝑓𝑎𝑛 − 𝐵𝑜𝑙𝑡𝑧𝑚𝑎𝑛𝑛 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 5.67 × 10−8
𝑚2 − 𝐾4
Steam pipes are very important in engineering application and are widely used. The main
applications include household boilers, industrial steam generating plants, locomotives, steam
engines, different building works, etc. to name but a few. Lack of proper insulation results in
large energy losses which in turn cost a lot of money over time. Without proper insulation, the
amount of energy lost can be 10 times greater than the energy being delivered through those
pipes.Insulation is defined as those materials or combinations of materials which retard the flow
of heat energy by performing one or more of the following functions:

1. Conserve energy by reducing heat loss or gain

2. Control surface temperatures for personnel protection and comfort

3. Facilitate temperature control of a process

4. Prevent vapor flow and water condensation on cold surfaces

6
5. Increase operating efficiency of heating/ventilating/cooling, plumbing, steam, process and
power systems found in commercial and industrial installations

6. Prevent or reduce damage to equipment from exposure to fire or corrosive atmosphere.

The temperature range within which the term "thermal insulation" applies is from –
73.3ºC (– 100ºF) to 815.6ºC (1500ºF). All applications below –73.3ºC (–100ºF) are termed
"cryogenic" and those above 815.6ºC (1500ºF) are termed "refractory". In analogy to electrical
resistance, the overall effect of an insulator can be described in terms of its “thermal resistance”.
The higher the thermal resistance the less the heat flow for a given temperature difference across
the insulator, just as the higher the electrical resistance the less the current flow for a given
potential difference across a resistor.

An engineer wishes to insulate bare steam pipes in a boiler room to reduce unnecessary
heat loss and to prevent people from burning themselves. After putting a thin layer of insulation
material onto a pipe the engineer is surprised to find the heat loss actually increases. This is
because there are two competing effects at work. Theinsulating material does, indeed, increase
the thermal resistance to heat flow out of the pipe. However, it also increases the surface area
that dissipates heat to the surrounding environment. Initially, the increase in heat transfer area
outweighs the increase in thermal resistance. As more insulation is added the heat loss reaches a
maximum and then decreases as the thermal resistance eventually wins out.

In the experiment, the researcher will focus on steam-condensation method as there are
three pipes, one is bare, the other one is partly covered with insulator, and the last one is fully
covered with insulator. Below are the formulas needed for the experiment.

• Solving for Heat Loss:

𝑄𝑥 = 𝑚𝑥 (ℎ𝑠 − ℎ𝑓𝑥 ) Equation 7

𝑥 = 𝐵 𝑖𝑓 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑏𝑎𝑟𝑒 𝑝𝑖𝑝𝑒

𝑥 = 𝑃 𝑖𝑓 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡𝑙𝑦 𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑝𝑖𝑝𝑒

𝑥 = 𝐹 𝑖𝑓 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑓𝑢𝑙𝑙𝑦 𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑝𝑖𝑝𝑒

7
Note: ℎ𝑠 is not at superheated state. Hence determine the enthalpy at liquid and mixture state and
use the quality from the previous experiments (97.04%)

• Solving for efficiency of insulation:

𝑄𝐵 − 𝑄𝑥 Equation 8
𝑒𝑓𝑓. = ( ) × 100%
𝑄𝐵
𝑥 = 𝑃 𝑖𝑓 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡𝑙𝑦 𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑝𝑖𝑝𝑒

𝑥 = 𝐹 𝑖𝑓 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑓𝑢𝑙𝑙𝑦 𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑝𝑖𝑝𝑒

8
LIST OF APPARATUS
1. Steam Generator

2. Throttling Calorimeter

3. Mercury Manometer

9
4. Piping System

5. Thermometer Bulbs (4pcs)

6. Tin cans (3pcs)

7. Balance

10
8. Asbestos Gloves

9. Stop watch

11
PROCEDURES
1. Prepare all the apparatus needed for the experiment.

2. Open all drain pipes and relief valves.

3. Open the main steam valve in order to purge the condensate and the impurities.

4. After the purging process, close the relief valves and the drain valves.

5. Start timing the trial for 30mins.

6. Measure the weight of the tin cans before placing them in their respective drain valves.

12
7. Before the duration ends, record the temperature and pressure readings of the supply steam.

8. After the 30 minutes duration, open the pressure relief valve slowly until all pressure
releases.

9. Wait for about 2 minutes for condensation to occur.

10. Collect the condensate using the tin cans.

11. Determine the temperature of the condensate.

12. Measure the weights of the condensate.

13
13. Using steam tables, determine the enthalpy of the condensate (liquid state).

14. Compute for the unknown values using the formulas from Theory and Principles.

14
SET-UP OF APPARATUS

Set-up of the Experiment with the pipe with no insulation (bucket 1), pipe with insulation but
partly covered (bucket 2), and pipe with fully-covered insulation (bucket 3).

15
FINAL DATA SHEET

PIPE Psteam Tsteam X Mcondense(kg) Tcondense hf Q (kJ) Eff

(%)
(psi) (C) (%) (C) (kJ/kg)

Bare 44.7 136.46 97 527.2 81 339.10 1224.4799 0

Partly 44.7 136.46 97 0.2301 85 355.9 421.2715 65.60

Covered

Fully 44.7 136.46 97 0.1901 84 351.70 347.4255 71.63

Covered

16
SAMPLE COMPUTATIONS
Enthalpy of Condensate

𝐻𝑓𝐹 @ 81˚𝐶 = 339.10 𝑘𝐿/𝑘𝑔

Enthalpy of Steam

ℎ𝑠 @ 134.46˚𝐶 = ℎ𝑓2 + 𝑥ℎ𝑓𝑔2 = 2661.7098 𝑘𝐽/𝑘𝑔

Change in Enthalpy

𝑘𝐽 𝑘𝐽
𝛥ℎ = ℎ𝑠 − ℎ𝑓1 = 2661.7098 − 339.10
𝑘𝑔 𝑘𝑔

Heat Loss in Pipes

𝑘𝐽
𝑄𝑏𝑎𝑟𝑒 = 𝑚𝑏 𝛥ℎ = 0.5272𝑘𝑔 (2322.6098 ) = 1224.4799 𝑘𝐽
𝑘𝑔

𝑘𝐽
𝑄𝑝𝑐 = 𝑚𝑝𝑐 𝛥ℎ = 0.1827𝑘𝑔 (2305.8078 ) = 421.2715 𝑘𝐽
𝑘𝑔

𝑘𝐽
𝑄𝑓𝑐 = 𝑚𝑓𝑐 𝛥ℎ = 0.1504𝑘𝑔 (2310.0098 ) = 347.4255 𝑘𝐽
𝑘𝑔

Heat Insulation Efficiency of Pipes

𝑄𝐵 − 𝑄𝐵
𝐸𝑓𝑓.𝐵 = 𝑥100% = 0%
𝑄𝐵

𝑄𝐵 − 𝑄𝑃𝐶
𝐸𝑓𝑓.𝑃𝐶 = 𝑥100% = 65.60%
𝑄𝐵

𝑄𝐵 − 𝑄𝐹𝐶
𝐸𝑓𝑓.𝐹𝐶 = 𝑥100% = 71.63%
𝑄𝐵

17
DISCUSSION OF RESULT

Based on the data gathered by the researcher, there are three set-up of pipe in which the
two are covered with insulation which are partly and fully covered. The pressure of the steam
line is constant for all set-up (44.7 psia) as well as its temperature (108 degrees Celsius). The
researcher used 97% as the steam quality which was calculated from the previous experiments.
From steam tables, the enthalpy of steam was determined using the steam line pressure. No
interpolation needed for the determination of enthalpy since the steam line pressure has an exact
value in the steam tables. The experiment was done in 30 minutes as condensate were released
from the pipes with their corresponding temperature. The temperature of the condensate at bare
pipe is the same as the temperature of pipes partly and fully covered since all the pipes were
connected at one steam line. The mass of condensate at the bare pipe holds the largest amount of
condensate in kilograms compared to the other two. The enthalpy of the condensate were
obtained using steam tables which is in liquid form. Since the heat loss was affected by the mass
of the condensate gathered, the bare pipe has the highest amount of heat loss followed by the
partly-covered pipe and the fully-covered pipe has the least amount of heat loss. The insulation
efficiency signifies the efficiency of an insulator to prevent heat losses and from the data
gathered by the researcher, it is obvious that heat loss is prevented by insulating the pipe fully-
covered as its insulation efficiency is highest among the three. Thus, the amount of heat loss was
minimized when the pipe is fully-covered with insulation which is expected throughout the
experiment.

18
QUESTION AND ANSWERS
1. An insulated steam pipe located where the ambient temperature is 32 degrees Celsius, has an
inside diameter of 50 mm with 10 mm thick wall. The outside diameter of the corrugated
asbestos insulation is 125 mm and the surface coefficient of still air, ho = 12 W/m2-K. Inside the
pipe is steam having a temperature of 150 degrees Celsius with film coefficient hi = 6000 W/m2-
K. Thermal conductivity of pipe and asbestos insulation are 45 and 0.12 W/m-K respectively.
Determine the heat loss per unit length of pipe.

∆𝑇
𝑄=
𝑅𝑇
𝑟 𝑟
1 ln (𝑟2 ) ln (𝑟3 ) 1
1 2
𝑅𝑇 = + + +
𝐴𝑖 ℎ𝑖 2𝜋𝐿𝑘1 2𝜋𝐿𝑘2 𝐴𝑜 ℎ𝑜
35 62.5
1 ln (25) ln ( 35 ) 1 0.98345
𝑅𝑇 = + + + =
𝜋(0.05)𝐿(6000) 2𝜋𝐿(45) 2𝜋𝐿(0.12) 𝜋(0.125)(𝐿)(12) 𝐿
150 − 32 𝑄 𝑊
𝑄= 0.98345 → = 120
𝐿 𝑚
𝐿

2. A pipe 200 mm outside diameter and 20 m length is covered with a layer, 70 mm thick of
insulation having a thermal conductivity of 0.05 W/m-K and a thermal conductance of 10 W/m2-
K at the outer surface. If the temperature of the pipe is 350 degrees Celsius and the ambient
temperature is 15 degrees Celsius, calculate the external surface temperature of the lagging.

𝑄𝑙𝑎𝑔𝑔𝑖𝑛𝑔 = 𝑄𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑙𝑚

2𝜋𝑘𝐿(𝑇1 − 𝑇2 )
𝑟
= 𝜋𝑑2 𝐿ℎ(𝑇2 − 𝑇3 )
ln (𝑟2 )
1

2𝜋(0.05)(350 − 𝑇2 )
170
= 𝜋(0.340)(10)(𝑇2 − 15) → 𝑇2 = 32.6℃
ln (100)

3. Steam, initially saturated at 2.05 MPa, passes through a 10.13 cm standard steel pipe for a total
distance of 152 m. The steam line is insulated with 5.08 cm thickness of 85% magnesia. For an

19
ambient temperature of 22 degrees Celsius, what is the quality of steam which arises at its
destination if the mass flow rate is 0.125 kg steam per second? Properties of steam:

Pressure Temperature hf hfg hg

2.05 MPa 213.67 degrees 914.52 kJ/kg 1885.5 kJ/kg 2800.00 kJ/kg
Celsius

Note: k for 85% magnesia is 0.069 W/m-K and ho = for still air is 9.36 W/m2-K.

𝑟1 = 5.05 𝑐𝑚; 𝑟2 = 10.13 𝑐𝑚

𝑡𝑖 − 𝑡𝑜
𝑄= 𝑟 ; 𝐴𝑜 = 2𝜋𝑟2 𝐿 = 2𝜋(10.13)(152) = 96.746 𝑚2
ln( 2 ) 1
𝑟1
+𝐴
2𝜋𝑘𝐿 𝑜 ℎ𝑜

213.67 − 22
𝑄= 0.1013 = 16,427.4 𝑊 = 16.43 𝑘𝑊
ln( ) 1
0.0505
+ (96.746)(9.36)
2𝜋(0.069)(152)

𝑘𝐽
from Q = m(ℎ2 − ℎ1 ) → 16.43 = 0.125(2800 − ℎ2 ) → ℎ2 = 2668.6
𝑘𝑔

ℎ2 = ℎ𝑓 + 𝑥ℎ𝑓𝑔

𝑘𝐽 𝑘𝐽 𝑘𝐽
2668.6 = 914.52 + 𝑥 (1885.5 ) → 𝑥 = 92.998%
𝑘𝑔 𝑘𝑔 𝑘𝑔
4. Compute the amount of condensate formed during 10 minutes warm-up of 150 m pipe
conveys saturated steam with enthalpy of vaporization hfg = 1947.8 kJ/kg. The minimum external
temperature of pipe is 2 degrees Celsius and the final temperature is 195 degrees Celsius. The
specific heat of pipe material is 0.6 kJ/kg-K and the specific weight is 28 kg/m.

𝑄𝑠𝑡𝑒𝑎𝑚 = 𝑄𝑝𝑖𝑝𝑒

𝑚𝑠 (ℎ𝑔 − ℎ𝑓 ) = [𝑚𝑐∆𝑇]𝑝𝑖𝑝𝑒

𝑚𝑠 (1947.8) = 150(28)(0.60)(195 − 2) → 𝑚𝑠 = 249.69 𝑘𝑔

5. A pipe with an outside diameter of 2.5 in. is insulated with a 2 in. layer of asbestos (k = 0.396
Btu-in/hr-ft2-F), followed by a layer of cork 1.5 in. thick (k = 0.30Btu-in/hr-ft2-F). If the
temperature of the outer surface of the cork is 90 degrees Fahrenheit and the inner temperature of
290 degrees Fahrenheit, calculate the heat lost per 100 ft. of insulated pipe.

20
 (𝑇1 − 𝑇3 ) 290 − 90 𝐵𝑡𝑢
𝑄= 𝑟 𝑟 = 3.25 4.75 = 2847.42
ln( 2 )
𝑟1
ln( 3 )
𝑟2
ln(
1.25
) ln(
3.25
) ℎ𝑟
+ 2𝜋𝑘 0.396 + 0.30
2𝜋𝑘𝑎 𝐿 𝑐𝐿 2𝜋( )(100) 2𝜋( )(100)
12 12

21
CONCLUSION

The researcher was able to determine the insulation efficiency of pipes when partly-
covered and fully covered using steam as the heating medium. It was founded out that a pipe
with fully-covered insulation has the least amount of heat loss compared to the other two set-up.
Steam is generally used for heating purposes and power generation by utilizing steam turbines.
In designing a power plant, an engineer should consider the factors that affects heat losses which
includes heat losses in pipes. It is impractical to install a bare pipe and let the steam pass through
it since heat escapes from the surface of the pipes. Insulators plays an important role for the
prevention of heat losses. In the experiment, heat loss is affected by variables such as the amount
of condensate produced since the difference in enthalpies were the same for the different set-up
as well as the material used for insulation. As a researcher, the accuracy of the work depends on
the proper procedures performed as well as the condition of the equipment. The mass of the
condensate must be determined accurately so that the researcher will be able to gather a more
accurate data that will provide a clearer results after the experiment. Safety must also observed
inside the laboratory since the researcher deals with hot condensate. PPE must be worn all the
times and it should be recommended in all mechanical engineering laboratory classes in order to
lessen the impact of accidents.

22
REFERENCES

• Heat Transfer. (2018). Retrieved from https://www.brighthubengineering.com/hvac/5231-

what-is-heat-transfer/
• Conduction Heat Transfer. (2018). Retrieved from
http://www.edinformatics.com/math_science/how_is_heat_transferred.htm
• Convection Heat Transfer. (2018). Retrieved from http://hyperphysics.phy-
astr.gsu.edu/hbase/thermo/heatra.html
• Radiation Heat Transfer. (2018). Retrieved from
https://www.engineeringtoolbox.com/radiation-heat-transfer-d_431.html
• Steam Pipe Insulation. (2018). Retrieved from
https://www.raeng.org.uk/publications/other/2-steam-pipe

23