INSTRUCTION MANUAL

FOR

HORIZONTAL CONDENSER APPARATUS

Manufactured by

OBJECTIVE:
Estimation of overall heat transfer coefficient experimentally for Horizontal and Vertical
condenser and compare the results with that of the standard correlation.

INTRODUCTION:

When a saturated vapor is brought in contact with a cooler surface, condensation occurs.
Condensation occurs at different rate of heat transfer by either of the two distinct physical
mechanism, drop and film wise condensation. The occurrence of drop or film wise
condensation depends largely on the characteristics of the condensing vapor and the
surface available for condensation. The condensing film coefficient is influenced by the
texture of the surface on which the condensation occurs and also by whether the
condensing surface is mounted vertically or horizontally. The heat transfer coefficients
obtained during film wise condensation are 1/5 th to1/6th of that in drops wise
condensation. Most practical cases correspond to mixed condensation. However, due to
lack of control in drop wise condensation, calculations are mostly based on film
condensation heat transfer coefficients.

THEORY

FOR VERTICAL CONDENSER

In case of condensation on the surface of a vapor tube, as in vertical condensers, the

condensate film flows downwards under the influence of gravity, but is retarded by the
viscosity of the condensate film. The flow is normally streamlined and heat flows through
the film by conduction only. In vertical tube, about 60% of the vapor condenses in the
upper half of the tube. Nusselthas derived a theoretical relation for the determination of
film heat transfer coefficient in terms of physical properties of condensate film,
characteristic dimension and the temperature driving force.

Assumptions:
1. Both the plate and the vapor are maintained at constant temperatures of Tw and Tsat,
respectively, and the temperature across the liquid film varies linearly.
2. Heat transfer across the liquid film is by conduction only.
3. The velocity of the vapor is low (or zero) so that it exerts no drag on the condensate
(no viscous shear on the liquid–vapor interface).
4. The flow of the condensate is laminar (Re<30) and the properties of the liquid are
constant.
5. The acceleration of the condensate layer is negligible
The film coefficient for condensation over a vertical plate of height L is given by –
 ( )
3 2
k ρ gλ
Ho=0.943 ¼ … … … . ( 1)
LμΔT

VERTICAL & HORIZONTAL CONDENSER

Film coefficient for condensation outside of vertical tube is given by:

hoD D ³ ρ ² g 0.56
=0.0077(kL ∆ T / D λ µ ¿ 0.67.( ¿ …….(2)
k μ

The physical properties are evaluated at film temperature, T

3 3
Tf =(Th− (Th−Tw ))= Th− ΔT ……… (3)
4 4

FOR HORIZONTAL CONDENSER

The value of the condensing coefficient for a given quantity of vapor, on a surface is
significantly affected by the position of the condenser. Provide that the condensate film is
flowing under laminar flow condition; the average condensing coefficient in case of a
horizontal condenser is around three times as great as the vertical coefficient. Nusselt has
derived a theoretical relation for the determination of film heat transfer coefficient in
terms of physical properties of condensate film, characteristic dimension and the
temperature driving force.

The film coefficient for condensation over a horizontal cylinder of outer diameter D

( )
3 2
k ρ gλ
ho=0.729 . ¼
D μΔT

Film coefficient for condensation over N number of horizontal tubes of dia. D is given
by:
3 2
k ρ gλ
hN =0.729( ¿¼
N ⅔ μΔT D

The physical properties are evaluated at film temperature, T

 3
Tf =(Th− (Th−Tw ))
4

DESCRIPTION

The set up consists of two tube bundle heat exchangers housed in a stainless steel shell,
one mount horizontally and the other vertically. Water passes through the tubes and
steam condenses over the tubes. Steam is supplied to the condenser from a steam
generator. The condensate is removed through the steam trap. A valve arrangement
allows selecting steam flow into either the vertical or the horizontal condenser.
Experiment can be conducted on any one of the condenser at a time. The continuous
cooling water supply can also be routed to any of the condensers as required. The heat
input by the heater in the steam generator is controlled by the Digital Temperature
Controller. Six numbers of temperature sensors are provided to measure the inlet and
outlet temperatures of the fluid.

TEMPERATURE SENSORS POSITIONS ARE GIVEN BELOW:T

T1 = Steam inlet for Horizontal/Vertical Condenser

T2 = Steam outlet for Horizontal Condenser.

T3 = Steam outlet for Vertical Condenser.

T4 = Water inlet for Horizontal Condenser.

T5 = Water outlet for Horizontal Condenser.

T6= Water inlet for Vertical Condenser.

T7= Water outlet for Vertical Condenser.

EXPERIMENTAL SETUP

Experiment Procedure :

Starting Procedure:

1. The steam generator is filled with water up to ¾ of its capacity.

2. The digital temperature indicator is set at 110°C.
 3. The steam generator valve is closed and time is allowed for steam formation.
4. One of the condensers is connected with cold water supply system.
5. The calibration of the Rota meter provided for measurement of water flow rate is
checked using a measuring cylinder and stopwatch.
6. When steam is formed, the supply of cold water is started to the condenser at any
flow rate fixed by means of the Rota meter.
7. The steam supply to the condenser is started and also a stopwatch is started at the
same instant.
8. The condensate is collected and measured using a measuring cylinder and
stopwatch.
9. The inlet and outlet temperatures of the cold water supply are noted. The
temperature of the condensate is also recorded.
10. The above steps as above may be repeated with different flow rates to give another
set of readings.
11. The entire process is then to be repeated for the other condenser, to allow
comparative study of the results for two types of condensing arrangements.
closing procedure :
12. At the end of the experiment, the power supply to the heater is switched off.Also
the mains power supply is switched off.
13. The vent provide on the steam generator is opened slightly to release pressure.
14. The supply of cooling water is disconnected.
15. After the vapors condense, the condensers and steam generator are to be drained.

EQUIPMENT DATA:

Number of tubes N: 4

Tube length L: 500 mm

I.D. of tube d=9.5 mm

O.D. of tube D: 12.7 mm

Inside diameter of shell D=108 mm

Outside diameter of shell D=114 mm

Length of shell L: 500 mm (approx.)

Condensate Measurement: Measuring Cylinder & Stopwatch

Water Flow Measurement: Rota meter, measuring cylinder &Stop Watch.

Temperature sensors: 7 Nos.

FORMULAE:

FOR VERTICAL CONDENSER:

1. The film coefficient for condensation over a vertical plate of height, L, is given by:
k ³ ρ² gʎ
ho=0.943( )¼ (1)
LμΔT

2. Film coefficient for condensation outside of vertical tube is given by:

hoD D ³ ρ ² g 0.56
=0.0077(kL ∆ T / D λ µ ¿ 0.67.( ¿
k μ

3. The physical properties are evaluated at film temperature, Tf, where

3 3
Tf =(Th− (Th−Tw ))= Th− ΔT
4 4

4. The heat balance between the amount of heat given to water by steam and the amount
of heat actually taken by the cooling water is obtained from the equation

Q= mCp (Tco-Tci)=w λ

5. The overall heat transfer coefficient is calculated from equation:

U =mCp . ¿

ΔTi− ΔTo
LMTD =(∆T1)=
ln( ΔTi/ ΔTo)

ΔTi = Thi – Tco

ΔTo = Tho - Tci (for counter flow)

Thi = Temperature of steam inlet.

Tho = Temperature of condensate stream.

Tci = Temperature of cold water input.

Tco = Temperature of cold water output.

.FOR HORIZONTAL CONDENSER:

 1. . Film coefficient for condensation over N number of horizontal tubes of dia., D is
calculated from:
3 2
k ρ gλ
hN =0.729( ¿¼
N ⅔ μΔTD
2. The physical properties are evaluated at film temperature, T
3
Tf =(Th− (Th−Tw ))
4
The heat balance between the amount of heat given to water by steam and the
amount of heat actually taken by the cooling water is obtained from the equation:

Q= mCp (Tco-Tci)=w λ

5. The overall heat transfer coefficient is calculated from equation:

U =mCp . ¿

ΔTi− ΔTo
LMTD =(∆Tm)=
ln( ΔTi/ ΔTo)

ΔTi = Thi – Tco

ΔTo = Tho - Tci (for counter flow)

Nomenclature:

𝞺 = density of condensate, kg/m3

𝞴 = latent heat of vaporization of J/gm average temp. of steam & water

μ = viscosity of condensate

A = heat transfer area

Do = OD of tube

g = acceleration due to gravity, m/sec2

ho = individual heat transfer coefficient, W/m2 0C

k = thermal conductivity of condensate at average temperature of steam

condensed, W/m0C

L = Length of the tubes

m = Cooling water rate

N = number of tubes

Tf = average temperature of steam condensate.

Tw = wall temp. = temperature of outlet condensed steam.

Th = temperature of the condensing vapor.

Thi = temperature of steam inlet.

Tho = temperature of condensed steam.

Tci = temperature of cold water input.

ΔTlm = log mean temperature difference.

U = overall heat transfer coefficient.

w = rate of condensation

PRECAUTIONS:

 Check the water level in the steam generator tank before turn on the heater for steam
generation.
 Both condensers cannot be operated at the same time. Either one of them can be
operated first
 Make sure that steam and water valves of the non-running condenser in OFF position
 Release the steam from steam generator once experiment is over.

Observation table
For Vertical Condenser

S.No steam T1 T2 cooling T3 T4 rate of

pressure water condensation
flow rate (w)
lpm
For Horizontal Condenser

S.No steam T1 T5 cooling T6 T7 rate of

pressure water condensation
flow rate (w)
lpm