44

CHAPTER 3
EXPERIMENTAL INVESTIGATION
3.0 Introduction
From the literature review it is observed that there are a
number of variables that control the heat transfer rate in impingement
cooling and play an important role in the fluid flow. Most important
parameters are the fluid velocity, geometry of nozzle, spacing between
the nozzle and target plate, temperature of the fluid and the target
plate. To conduct an experimental investigation in which there are
several variables like this, it is necessary to develop a test facility
keeping all the operational requirements in mind.

3.1 Experimental test facility

As a part of the present investigation an experimental test
facility is designed, developed, tested and commissioned. The facility
consists of four sub systems namely:
(1) Fluid flow measurement and monitoring system,
(2) Heat flow regulating system,
(3) Instrumentation system, and
(4) Data acquisition and storage system.
These subsystems are integrated to form the final experimental
facility, shown diagrammatically in Fig.3.1.

45

Fig. 3.1 Schematic diagram of experimental test facility

3.1.1 Fluid flow measurement and monitoring system

A two stage reciprocating air compressor driven by a prime
mover DC motor through a belt is shown in Fig.3.2. The test rig
consists of base on which the tank (air reservoir) is mounted. The out
let of the air compressor is connected to the reservoir at 20-bar
pressure and 160 liters capacity. The temperature and pressure of the
compressed air is indicated by a thermometer and a pressure gauge
respectively. The suction is connected to the air tank through a
calibrated orifice plate with a water manometer for facilitating the flow
measurement. During the experiment, air is drawn from the reservoir
through the rotameter and led subsequently to the manifold, to which
the nozzles are attached. Two rotameters are employed parallely, one
for the larger mass flow rates, (0-150 LPM) and the other one for low

46
(0-30 LPM) mass flow rate. The flow rate is measured with rotameters,
calibrated as per ASME standards with 1% accuracy. The system
also includes of regulating valves to change the flow rate as per the
operational requirements.

Fig.3.2 Schematic diagram of two stage air compressor

47

3.1.2 Heat flow regulating system

Fig.3.3 Schematic diagram of heat flow regulating system

Heat flow regulating system consists of a stabilized power
supply from UPS, a dimmerstat to vary the voltage and a voltmeter (0
to 250 V) and an ammeter (0 to 200 mA) to indicate the supply voltage
and current to the 500W heater plate. The heater plate is a 240 mm
diameter and 20 mm thick is shown in Fig.3.3. The temperature of the
hot plate (Target plate) can be regulated by changing the supply
voltage.

3.1.3 Instrumentation system

Present experimental setup consists of thermocouple sensors to
measure temperature at various locations and an eight channel
temperature scanner (M83 BP 407, Masibus Digital Scanner 85XX) to

48
record the corresponding temperatures. The programming, calibration
and the operation of the scanner are accomplished by nine simple
keys with two independent displays for channel no and data value for
the channel. Channel display is of two digits to differentiate it from
data display of four digits. Each of 0.56 seven segments LED is
shown

schematically

in

Fig.3.4.

J-

Type

thermocouple

(Iron-

constantan) would normally have an error of approximately 0.1% of

the target temperatures when used in the temperatures ranging from
0 to 400 0C. These types of thermocouples are used for temperature
measurement due to their excellent sensitivity.

Fig.3.4 Schematic diagram of instrumentation facility

49

3.1.4 Calibration of temperature sensors (Thermocouples)

Fig.3.5 Schematic diagram of calibration setup

A schematic diagram for the arrangement for temperature

calibration setup, used in the present investigation is shown in
Fig.3.5. The temperature sensors used in the present experimental
investigation (J-type thermocouple) are properly calibrated as per the
standard procedure, described in detail in the following section. J-type
thermocouples, are drawn from a single spool are cut to the required
sizes based on the distance between the measuring point and the
temperature scanner. Thermocouple beads are formed by gas welding
technique in a nitrogen environment. This ensures formation of beads
with out metal oxide coating on the surface of the bead. Thermocouple
beads thus formed are given a varnish coating to prevent electric short
circuiting between the sensor and the measured. A representative
thermocouple is arbitrarily selected and calibrated in the range of 0 to

50
2000C. The bead is dipped in a thermo fluid and the cold junction of
the thermocouple is connected to a precision volt meter through a ice
melting bath that served as a zero temperature reference. The
temperature of the thermic fluid is gradually increased with an electric
heater. The temperature of thermic fluid is measured with a standard
reference thermometer with an accuracy of 0.10C. The e.m.f.
developed at the cold junction is recorded with the precision
multimeter. The data thus generated, is used to draw the calibration
graph between the input temperature and output voltage. The output
voltage is in turn used to measure the temperature of the measurand.
The calibration data for J-type thermocouples used in experiment is
given in Table 3.1.and Table 3.2.

Table 3.1
Details of instrument calibrated:
MAKE/TYPE
J TYPE
THERMOCOUPLE

TAG NO.

SR.NO

MJIT-01

TM-TC-01

Environmental conditions:

RANGE
0-200
DEG.C

ACCURACY
0.5%

Room Temperature: (23 20C)

Humidity : (55 5% RH)

Details of standard used:

MAKE & TYPE

SR.NO

Temperature
Bath with
Honey-Well
controller

DC10
10

RANGE

04000C

ACCURACY
SPECIFIED

0.1%

CAL.REPORT
NO

Cal/0601/116
7

NEXT CAL

30/7/08

51

Table 3.2
1. Calibration values for thermo-couple (TC-01)
S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
0
0
Temperature( C) Temperature( C) Temperature(0C)
50
50.0
50.2
+0.2
100
100.0
100.1
+0.1
150
150.0
150.1
+0.1
200
200.0
199.8
-0.2

2. Calibration values for thermo-couple (TC-02)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
Temperature(0C) Temperature(0C) Temperature(0C)
50
50.0
49.6
-0.4
100
100.0
99.8
-0.2
150
150.0
149.7
-0.3
200
200.0
199.6
-0.4

3. Calibration values for thermo-couple (TC-03)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
0
0
Temperature( C) Temperature( C) Temperature(0C)
50
50.0
50.2
-0.2
100
100.0
100.1
+0.1
150
150.0
150.1
+0.1
200
200.0
200.2
+0.2

4. Calibration values for thermo-couple (TC-04)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
Temperature(0C) Temperature(0C) Temperature(0C)
50
50.0
50.3
+0.3
100
100.0
100.3
+0.3
150
150.0
150.1
+0.1
200
200.0
200.1
+0.1

5. Calibration values for thermo-couple (TC-05)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
0
0
Temperature( C) Temperature( C) Temperature(0C)
50
50.0
49.7
-0.3
100
100.0
99.7
-0.3
150
150.0
149.6
-0.4
200
200.0
199.5
-0.5

52
6. Calibration values for thermo-couple (TC-06)
S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
0
0
Temperature( C) Temperature( C) Temperature(0C)
50
50.0
49.8
-0.2
100
100.0
99.9
-0.1
150
150.0
150.1
+0.1
200
200.0
200.2
+0.2

7. Calibration values for thermo-couple (TC-07)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
Temperature(0C) Temperature(0C) Temperature(0C)
50
50.0
50.1
+0.1
100
100.0
100.2
+0.2
150
150.0
150.3
+0.3
200
200.0
200.4
+0.4

8. Calibration values for thermo-couple (TC-08)

S.No
1
2
3
4

Set
Actual
Observed
Error(0C)
0
0
Temperature( C) Temperature( C) Temperature(0C)
50
50.0
50.2
+0.2
100
100.0
100.2
+0.2
150
150.0
150.3
+0.3
200
200.0
200.3
+0.3

53

Fig.3.6 Comparison of observed temperature values with set

temperature values

The present observed temperature values are validated against

the set temperatures for the calibration of thermocouples (J-type) in
Fig.3.6. It can be observed from Fig.3.6 that both temperatures agree
well, indicating that the thermocouples can be confidently used for
further experimentation.

54

3.1.5 Data acquisition and storage system:

The

Data

acquisition

system

consists

of

eight

channel

temperature scanner (masibus digital scanner 85 XX). A custom built

software capable of acquiring temperature data as a function of time is
loaded on to a personal computer (P4). This software has a provision to
set the sampling frequency of temperature as low as 0.1 sec. The
storage capacity of the data acquisition system is kept sufficiently
large so that the temperature data can be acquired over large interval
of time.

Fig.3.7. Schematic diagram of data acquisition facility

3.2 Description of the experimental setup

A Schematic diagram and photographic view of the experimental
setup are presented in Fig. 3.8 and Plate.3.1 respectively (please see
Annexure I, for other details). The important components in the

55
setup are two stage reciprocating air compressor, rotameter, electric
heater, and control panel. The control panel consists of voltmeter,
ammeter, dimmer stat, and temperature display unit. An aluminum
heater plate rated 500 W and 240 V, insulated on all sides by mica
sheets, is used to heat the printed circuit board (PCB). Five cylindrical
electrical resistors fixed on printed circuit board of diameter 100mm
and 2mm thick are located centrally on the aluminum heater plate. A
chip assembly on PCB is simulated with the electrical resistors which
are 25 mm long and 5 mm in diameter.
The power is supplied to the heater through the dimmerstat to
control the heating rate to the base plate. The current flow and voltage
are measured by ammeter and voltmeter respectively. Teflon coated Jtype thermocouples are used to measure the surface temperatures of
the electronic components (resistors). The location of thermocouples
on the resistor is shown in Fig. 3.9.
The central resistor in the jet array is considered for the
analysis. Two thermocouple leads are inserted into the holes drilled to
the aluminum heater plate. The gap between resistors is filled with
aluminum powder to ensure good thermal contact between the
resistors. One thermocouple is used exclusively to measure the
temperature of the air in the enclosure. All these eight thermocouples
are connected to a temperature display unit through a scanner to
observe the readings and store the values in a personal computer (P4).

Fig. 3.8. Schematic diagram of an experimental setup

56

Plate 3.1 Photographic view of an experimental setup

57

58
The air flow through the nozzles of different diameters located above
the resistors is measured with two types of rotameters. Air at 20-bar is
supplied to the nozzle from a reciprocating air compressor of 160 liter
storage capacity through the rotameters. Provision is made to vary the
distance between the nozzle tip and the test surface. The axis of the
nozzle is always aligned with the central resistor and is normal to the
plane on which heat sources are mounted. The velocity of jet is
measured using a Pitot tube and U-tube Manometer (water) to an
accuracy of 1 %.

Fig.3.9 Location of Thermocouples on resistor surface

59

Fig.3.10 Diagram of wire wound resistor

Specifications of wire wound resistor:
Heat capacity

Resistance

: 16 ohms

Tolerance

5 watt

: 1%

60

Plate 3.2 Photographic view of the test section with

500W heater and Aluminum plate

61

3.2.1 Range of parameters studied in the experiment

Three different jets are fabricated with 5mm, 8mm, and 10mm
diameters respectively. Resistor with 25mm length and 5mm diameter
are used to generate heat. The ranges of parameters covered are listed
below:

Surface temperature range, Ta, oC

30- 100

Diameter of nozzle, mm

5, 8, and 10

Nozzle-to-electronic components spacing

2 - 10

to nozzle diameter (H/d)

Experimental data are obtained for four different operating conditions

of the jet arrays as shown below.
(a) Circular nozzle with different Reynolds number and nozzle-totarget heater spacing.
(b) Rectangular nozzle with different Reynolds number and nozzle-totarget heater spacing.

(c) Square nozzle with different Reynolds number and nozzle-to- target
heater spacing.
(d) Different Radial locations with circular, rectangular and square
nozzles.

62

3.2.2 Types of nozzles used in the present investigation:

There are three different types of nozzles used in the present
investigation. They are Circular, Square and Rectangular nozzles.

(a)

(b)

(c)

Plate3.3 Photographic view of different circular nozzles: (a) d

=5 mm, (b) d = 8mm (c) d= 10mm

Plate 3.4 Photographic view of

square nozzle, de = 11.28mm

Plate3.5 Photographic view

of
68
rectangular nozzle, de = 13.3mm

63
Table 3.3
Geometry and dimensions of the nozzles
S.No

1
2
3

Type of
nozzles

Height
(mm)

Breadth
(mm)

*Equivalent
diameter
(de) (mm)

Circular

5,8 and
10

5,8 and
10

5,8 and 10

Square

10

10

11.28

10

Rectangular

20

13.3

Hydraulic
diameter
(d*) (mm)
5,8, and
10

*Equivalent diameter (de) is defined on the basis of area of the

nozzle
For square nozzle, Area = 10 x 10 mm2

d e 2 100
4
de = 11.28mm.
For rectangular nozzle, Area = 5 x 20 mm2
de = 13.3mm.
Hydraulic diameter (d*) is defined as =

For rectangular nozzle

4(area )
wetted perimeter
4x5x 20
2x 5 20

= 8mm.

64

Fig. 3.11 Schematic line diagram of different nozzles

65

3.3 Experimental procedure

The air jet issuing from the nozzle and impinging on the
resistors is depicted as free jet and wall jet regions respectively. Five
cylindrical electrical resistors fixed to an insulating plate (PCB) of
diameter 100mm and 2mm thick located centrally on an aluminum
heater plate is shown in Fig.3.12. Power is supplied to the resistors
through a step down transformer and for the aluminum plate through
a dimmer stat. The heat input to the aluminum plate is adjusted with
the help of dimmer stat. The temperatures at all the thermocouple
positions are recorded until steady state is reached. These data are
utilized for the calculation of steady state heat convection heat
transfer rate. The jet array is kept in three different geometric
orientations as mentioned above, and steady state temperatures are
noted for each orientation of the jet array.

Fig.3.12 Schematic diagram of flow emanating from the nozzle

impinging on resistors surface

66
The volumetric energy generation due to heating of the resistors
using AC current is assumed to be uniform. The temperature of the
resistors is allowed to rise up to 950 C and then cooled by forced
convection mainly from the top surface by the air stream flowing in
the wall jet region. The surface temperatures of the resistors are
recorded till they attain 450C. The procedure is repeated at different
flow rates of air with temperature values recorded in the different
Reynolds numbers. The heat loss from the resistors towards the
heater plate is assumed to be negligibly small. Experimental data as
mentioned above are obtained for jet arrays having five resistors.

3.4 Method and model calculation

A model calculation is presented below for the case of a vertical
jet array. The values of various parameters and the calculation
procedure are given below.

Ambient air temperature, Ta = 300 C

Thermal conductivity of the fluid, kf = 0.026 W/mK
Surface temperature of the electronic components =82

Kinematic viscosity of the fluid, f = 15.89 x 10-6 m2 /s

Prandthal number, Pr = 0.71
Density of the fluid, = 1.106 kg/m3

67
1. Velocity of the air on the surface of the electronic components
Reynolds number, Re = 5850 (arbitrary chosen)
Diameter of the nozzle, d = 5mm

Re

But

UOd

(3.1)

5850 =UOx5x10-3
15.89x10-6
UO= 18.59 m/sec

U O 0.98x 2x9.81x

h 1 h 2 1000
x
100
1.16

(3.2)

h1 h2 = 8.74cm
2. Mass flow rate:
For a constant above value of (h1-h2), the air is supplied on to the
surface of electronic components. Thus the required mass flow rate is
obtained and indicated by the Rotameter.
Required mass flow rate = 8LPM
Resolution of the manometer which is 1mm water column.
h1 = 19.96cm and h2 = 11.22cm
Required mass flow rate = 8 LPM
The mass flow rate of air is calculated making use of the following
equation:

m OV
Where, O

PO
RO TO
= 0.95
287x303

(3.3)

68
= 1.09 kg/m3

m 1.09x8 LPM
= 1.09x8x10-3
60
= 2.725x10-4 kg/sec
= 0.98kg/hr.
3. Local value of heat transfer coefficient ( h)
The local value of heat transfer coefficient (h) is obtained from the
following equation:
Nu 0.193Re

0.618

Pr0.33

hd
k air

(3.4)

0.193(5850)0.618 (0.71)0.33 = hx5x10-3

26.3x10-3
h =193 W/m2 K.

4. Heat transfer rate

The heat transfer rate (Q) is obtained from the following equation

Q = h AS (TS Ta )

(3.5)

= 193x (2.5x0.5x 10-4) x (82-30)

= 1.254 W.
5. Local Nusselt number
The local Nusselt number of the electronic component is calculated as
follows
Nu=

hd
k air

= 193x5x10-3
0.026
= 37.11

(3.6)

69
6. Recovery factor (rf)
The recovery factor is defined by ratio of the difference of recovery
temperature (Trt) and jet total temperature (Tjt) to the jet dynamic
temperature (Tdt).

rf

Trt Tjt
Tdt

(3.7)

= 80-28
71.8
= 1.24
7. Effectiveness ( )
The effectiveness is defined by the difference of adiabatic wall
temperature and recovery temperature to the difference of jet total
temperature and ambient temperature.

Taw Trt
T jt Ta

(3.8)

= 0.72
In the present experimental investigation the heat sources (electronic
components) are mounted on a printed circuit board. For all practical
purposes the printed circuit board may be assumed as an adiabatic
wall. In the present experimentations the reference temperature is
taken as the adiabatic wall temperature for calculations.

70

(a) Nozzle-to-electronic
resistor spacing to nozzle
diameter for circular
nozzle

(b) Nozzle-to-electronic resistor

spacing to nozzle equivalent
diameter with square nozzle

(c)

(d) Dimensionless radial locations

with circular, square and
rectangular nozzles

Nozzle-to-electronic
resistor spacing to
nozzle equivalent
diameter for
rectangular nozzle

Fig. 3.13. Jet array in different orientations.

71
3.5 Regression equations
The following equations are obtained from the experimental
results by nonlinear regression analysis for Nu0, stagnation Nusselt
number for theoretical and experimental analysis. Heat fluxes q (the),
q(exp) is evident that they can be used to calculate Q(the), Q(exp) of
the

jet array in

different orientations as a function of

system

parameters.
3.5.1. Different jet Reynolds number (Red) and the nozzle- to resistor
spacing with circular nozzle
(i) For 5mm diameter of the nozzle:
Nu Corr 0.2Re d

0.5

Pr 0.33 H

0.06

hd
k air

(3.81)

with an average deviation of (AD) = 8% and standard deviation of

(SD) = 9.9% .Eq.(3.81) is valid in the range 5850 < Red < 10000, Pr =
0.71, and 2 < H/d < 6.

Nu O 0.193Re d

0.6

Pr

hd
k air

0.33

(3.82)

(ii) For 8mm diameter of the nozzle:

Nu Corr 1.296Re d

0.4

Pr 0.4 H

0.012

hd
k air

(3.83)

over the ranges 7325 < Red < 12200, 0.69 < Pr <0.70 and 3 < H/d <8,
with an average deviation of (AD)= 8% and standard deviation of SD= 10%

hd
k air

NuO 0.683Red Pr
(iii) For 10mm diameter of the nozzle:
0.5

Nu Corr 1.38Re d

0.46

0.33

Pr

0.35

H

d

0.0147

hd
k air

(3.85)

72
with an average deviation of (AD) = 9% and standard deviation of (SD)
= 10.5% .Eq.(3.85) is valid in the range 5850 < Red < 12200, 0.70<Pr<
0.71, and 4 < H/d < 10.

NuO 0.86Red

0.5

hd
k air

Pr0.33

3.5.2. For square nozzle:

Nu Corr 0.61Re d

0.62

Pr 0.33 H

0.016

hd
k air

(3.87)

with an average deviation of (AD) = 8.5% and standard deviation of

(SD) = 11% .Eq.(3.87) is valid in the range 6500 < Red < 15000,
0.70<Pr< 0.71, and 3 < H/d < 10.

NuO 0.175Red

0.675

hd
k air

Pr0.33

3.5.3. For rectangular nozzle:

Nu Corr 1.61Re d

0.5

Pr

0.33

H

d

0.011

hd
k air

(3.89)

with an average deviation of (AD) = 9.8% and standard deviation of

(SD) = 12% .Eq.(3.89) is valid in the range 6500 < Red < 15000,
0.70<Pr< 0.71, and 3 < H/d < 10

Nu O 0.55Red

0.62

Pr 0.31

hd
k air

The regression equations i.e., Eqs. (3.8) to (3.90) predict the

experimental results with in a standard deviation of 10%, 10.5% ,
11% , 12%, and 13% respectively. The ranges of parameters
considered are 2< H/d< 10, and 5850< Re< 23000.