Theory of Heat Transfer

Heat – is defined as energy in transition due to a temperature difference

Methodsof heat transfer

1. Conduction – When the transition takes place because of contact of the particles of one or
more bodies.
2. Convection – When the energy is transferred because of the motion or mixing of the
particles of a fluid.
3. Radiation – energy through wave motion.

Steady Transfer of Heat:

The temperature at any point in any of the bodies is constant with time.

Conduction:

Fourier’s equation
&'
! = −$%
&(
) = ℎ+,--.,/01+..+2
3 = ,.+,45+.5+/26789,.:
- = -+;5+.,-8.+
< = -ℎ67=/+00
= = -ℎ+.;,97>/287-6?6-@

Assumptions:
1. Steady flow
No storage of energy
Isothermal-temperature of any point in the conducting material is constant with time
2. Homogeneous material
3. Unidirectional flow

Thermal conductivity (k)

• Pressure effect negligible
Vacuum – k is nearly zero
• K increase proportionally with Molecular weight
J
! K increases with temperature+<7+5-AB 0 32 − 200 ∝ ,H>?+ 250 ∝
• Insulating materials
Porous nature of material

From Fourier’s equation

&'
! = −$%
&(
P MN
L32-
K 2< = − K
Q MO )

1
 L34-1 − -6:
<=
)

$%4'R − 'S:
!=
(

Composite wall

)T,
-J − -B =
L,3

)TH
-B − -U =
LH3

)T7
-U − -V =
L73

) T, TH T7
4-J − -B : W 4-B − -U : W 4-U − -V : = X W W Y
3 L, LH L7

%4'Z − '[ :
!= ]^ ]_ ]`
\$^ W $_ W $`a

-J − -V
)=
b, W bH W b7

T
b= .+060-,/7+
L3

Cylindrical Wall
cM
) = −L3
cd
2-
) = −Le2f.gh
2.
ri
MN dN
r )2.
K 2- = − K
rf MO dO Le2f.gh

2
 eij$kh4'R − 'S :
!= nS
lm nR
Composite cylindrical wall

dB
)9/ dO
-O − -B =
ri 2fLg

r2 dN
)9/ dB
rf -B − -N =
2fLg

dB dN
) 9/ dO 9/ dB
4-O − -B : W o-B − -N p = q W r
2fg L, LH

dB dN
) 9/ dO 9/ dB
-O − -N = q W r
2fg L, LH

4ijk:4'R − 'S :
!= ni nS
lm lm
nR
W ni
$^ $_

Example 1
Determine the heat transferred through a composite plane wall area of 1 ft2 of carbon steel 1” thick
and magnesite brick 8” thick. Take the temperatures at 700℉ and 300℉.

From Fig 4-1(a)

tQQuUQQ
For a mean temp of = 500℉
B
L0 = 25
L; = 2

14700 − 300:
)= J z = 1188 |-85+.ℎ.
W
4JB×By: 4JB×B:

1188 × 8
- = 300 W = 696℉
12 × 2 × 1

696 W 300
-•€• = = 498℉
2

Actual mean is close to 5000F so from 4-1a ks and km is 25 and 2 respectively.

Example 2

3
Use the data in the previous example to determine the heat transferred through a steel pipe 1 ft long
and 1” thick with an ID of 1.12 ft and covered with 8” of magnesite brick.

4Bƒ„:4M… †M‡ :
)= Š‹ Š‡
ˆ‰
Š… uˆ‰Š‹
Œ• ŒŽ
•• = ‘• W 2- rf r2
241:
•• = 1.12 W
12
•• = 1.2867 ri
••
.2 =
2
.2 = 0.6433
‘• 1.12
.6 = = = 0.56
2 2
•• 1.2867 8
.1 = W -; = W = 1.31
2 2 12

42f41::4700 − 300: _'Ÿ

)= •.–—— ™.š™ = ›œ›œ. •ž›i
“” “” n
•.˜–
W •.–——
By B

Convection:

The figure shows a velocity profile of fluid flowing inside the tube. The middle shows the
highest velocity and the part touching the pipe is almost stagnant. Although for a convection to
happen a movement of particle is needed, the particle near the pipe is almost stagnant and the
analysis should be conduction. But since the thickness of the film is variable the analysis can be
convection
Stagnant film
Table 4-1
) = ℎ3o-N − -O p
Film coefficient

Combined Convection and Conduction

4
) = 1J ℎB 4-J − -B :

1B LU 34-B − -U :
)=
<

) = 1U ℎV34-U − -V :

) 1 < 1
-J − -V = X W W Y
3 1J ℎB 1B LU 1U ℎV

34-J − -V :
)= J P J
\J ¡ W W a
™ ‹ J‹ ¢š Jš ¡—

J
£= ™ ¥ ™ Overall thermal coefficient
\ u u a
™ ™ ¤ ‹ ™ ‹ Œš ™ š ¤ —

) = £34-J − -V :

Cylindrical wall
)
4-J − -B : =
ℎ¦ fg4••:

)
4-B − -U : = Bƒ¢„
§¨
“”
©¨

)
4-U − -V : =
ℎO fg4‘•:

1 1 1
4-J − -V : = ) ª W W «
ℎ¦ fg4••: Bƒ¢„
§¨
ℎ O fg4‘•:
“” ©¨

5
 4-J − -V :
)= §¨
J “” J
¡§ ƒ„4¦¬:
W Bƒ¢„
©¨
W ¡ ƒ„4-¬:
…

4-J − -V :
)= §¨
J ¦¬“” ¦¬ J
®¡ W B¢
©¨
W ¯
¡… 4-¬: ƒ„4¦¬:
§

3¦ = fg4••:

1
£¦ = §¨
J ¦¬“” ¦¬
W ©¨
W
¡§ B¢ ¡… 4-¬:

! = %° ±°4'Z − '[ :

Example 3
Calculate the overall coefficient of heat transfer U, and the quantity of heat transferred per hour
through and a lead tube 1ft long with a OD of 1” and an ID of 0.87”. Assume the hot fluid outside the
tube to be water at 150℉ with a film coefficient of 400 Btu per (sq ft)(hr)(℉:, and the cold fluid
inside the tube also water but at 130℉ with a velocity of 5fps.

1
£¦ = §¨
J ¦¬“” ¦¬
W ©¨
W
¡§ B¢ ¡… 4-¬:
From Table 4-1 Eq G
ℎ = 163² Q.zy 41 W .0104-:
|-8
ℎO = 16345:Q.zy 41 W .01044130:: = 1505.73
40)1-:4ℎ.:4℉:
1 |-8
£¦ = ™ ™ = 281.4132 B
J “” J 1- − ℎ. − ℉
W ™‹ •.³´
W
VQQ B×BQ Q.zt4JyQy:

f41:41:
3¦ = = 0.26181- B
12
|-8
) = 28240.2615:4150 − 130: = 1473.4764
ℎ.

Mean Temperature Difference

6
7
 From the previous equations of heat (q=AUΔT), the ΔT is not applicable to some equipment
in steam power plant. As shown in fig B to E, there are four temperatures known. For evaporator fig
A the previous equations can be used. The introduction of mean temperature difference would be
more appropriate for fig B to E.

! = ±%µ¶

Arithmetic mean temperature difference

4-J W -B : − 4-U W -V : ºJ W ºB
%·¸¹ = =
2 2
Log mean temperature difference
From slope
2» ºB − ºJ
=
2¼ )

2¼ = £º23

2» ºB − ºJ
=
£º23 )
»‹
2º £4ºB − ºJ : ½
K = K 23
»™ º ) Q

£34ºB − ºJ:
)= »‹
9/
»™

4ºB − ºJ :
µ¶ = k·¸¹ = »‹
9/
»™
! = ±%µ¶

Example 4
Calculate the LMTD and AMTD when hot fluid enters a heat exchanger at 150℉ and leaves at 90℉.

ºJ = 150 − 95 = 55 ¾
ºB = 90 − 89 = 10 ¾
55 − 10
g¿À• = yy = 26.4 ¾
ln JQ
55 W 10
3¿À• = = 32.5 ¾
2

Scale

8
 Glasslike scale – silicon
- Acts as insulation
Film coefficient for scales
In table 4-2
! = Ã %4'Z − 'i :

1
±Ä = §¨
J J ¦¬“” ¦¬ ¦¬
W W ©¨
W W
¡§ ¡ÅÆ B¢ ¡Å… 4-¬: ¡… 4-¬:

Condensing and Boiling

Condensation of a vapor on a metal

1. Dropwise - occurs when the vapor condenses as drops which are eventually removed
from the surface by gravity
2. Filmwise- occurs when a vapor condenses and forms a liquid film over the cool surface:
lower h

Vaporization
1. Nuclear boiling - consists of the formation of vapor bubbles on the hot surface
2. Film vaporization - evident when the heat head is too high

Radiation

Reflectivity – fraction of radiant energy reflected by a body

Absorptivity – fraction absorbed by the body
Transmissivity – transmitted through the body
Perfect Black Body – capable of emitting radiant energy at the same rate at which it is
capable of absorbing it.
Emissivity – the ratio of the rate of emission of radiant energy for that body to the rate of
emission for a perfect body.
À V
) = 0.1743 Ç È
100
À V
) = 0.1743É Ç È
100
Net energy
¸Z [ ¸i [
! = •. Zž[%Ê ®Ç È −Ç È ¯
Z•• Z••

*Valid only for a small body of any shape completely enclosed by a large body.

Example 5
Calculate the radiant-heat transfer to a room from 12ft of bare1 ½ in schedule 40 pipe
carrying steam at 225 ℉. The room is at 70℉ and the pipe is painted a light color (É = 0.9:

From plate1 page 675

9
 OD of 1.5 = 1.9in
1.9f ÀJ V ÀB V |-8
) = 0.17440.9:412: Ç È ®Ç È −Ç È ¯ = 1320.4953
12 100 100 ℎ.

Insulation Material

Reasons:
1. Reduce heat loss
2. Prevent sweating of cool surface
3. Reduce the possibility of injury

Examples of insulation materials:

1. Magnesium Carbonate
2. Asbestos
3. Diatomaceous Earth
4. Cork
5. Glass wool and rock wool
6. Aluminum foil
7. Hair felt
8. Refractories

Pipe Insulation
! = `n %o'R − 'S p

ℎËd = 7>;H6/+27>/?+7-6>/,/2.,26,-6>/7>+11676+/-

Fig 4-17
) = £Ì 3Ì o-O − -N p

1
£Ì = §¨
¦¬“” ¦¬
©¨
W
B¢ ¡ÍŠ 4¬:

*Neglect pipe wall and film

Insulation Efficiency
9>001.>;H,.+565+ − 9>001.>;6/089,-+2565+
=
9>001.>;H,.+565+

Example 6
Calculate the heat loss from, and the efficiency of 1 ½in of canvas covered rock wool insulation on a
4in pipe with 380℉ working temperature and 80℉ room temperature

From Plate 1 OD=4.5 in

For bare pipe
From Fig 4-17
380-80=300℉ and 4.5 in

10
 ℎËd = 3.25
4.5 |-8
) = 3.25f Ç È 41:4380 − 80: = 1148.6448
12 ℎ.96/+,.1-

For pipe with insulation assume the surface temperature of the canvas = 110℉
From Fig 4-17
110 − 80 = 30
• = 4.5 W 3 = 7.5
ℎËd = 1.8
= = 0.037

1
£Ì = —.˜ ´.˜ = 0.3422
“” V.y
™‹ —.˜
B4Q.QUt:
W t.y4J.z:

4.5 |-8
) = 0.3422f 41:4380 − 80: = 120.9435
12 ℎ.96/+,.1-

Check if assumed 110℉is close to the computed value

121
- − -N = t.y = 34.2
1.8f × 1
JB

- = 114.2℉ → 79>0+

121
+11676+/7@ = 1 − = 89.5%
1147

PROBLEMS

4-6 A composite furnace wall is formed of 8in of fire brick, 6in of diatomaceous earth, 4in of 85%
magnesia and 1/64in steel. Calculate the heat loss through the wall for 1ft2 of surface with surface
temperature of 1400℉ and 100℉.

-J W -y
= 750
2

11
*Thermal Conductivity from Fig 4-1
Fire brick = 0.6
Diatomaceous Earth = 0.066
85% magnesia = 0.05(project)
For steel = 25

34-J − -y :
)= Е ÐÑ ÐË Ðc
\¢• W ¢Ñ W ¢Ë W ¢ca

141400 − 100: |-8

)= zÒ ÓÒ VÒ JÒ 4JB: = 84.67076
ℎ.
JB
X Q.Ó JB
W Q.QÓÓ JB
W Q.Qy W ÓVBy Y

*Find the temp of each interface

Fire Brick
)<•
-B = -J −
3L•
z
84.67 Ô Õ
JB
-B = 1400 − = 1305.921372
140.6:

-B W -J
= 1352.96
2
Ö+×L• = 0.7

Diatomaceous Earth
)<Ñ
-U = -B −
3LÑ
Ó
84.67 Ô Õ
JB
-B = 1305.9 − = 664.4548075
140.6:

-B W -U 1970.376183
= = 985.18
2 2
Ö+×L• = 0.078

For 85% Magnesia

)<Ë
-V = -U −
3LË
-V = 99.983

-V W -U
= 382.81
2
Ö+×L• = 0.042

Steel is constant Lc =25

New )

12
 141400 − 100:
)=z ÓÒ VÒ JÒ 4JB: = 82.6027
ÒJB
W JB W JB W ÓV
Q.t Q.QtU Q.QVB By

Note: more iteration to find for the exact K

4-11 Calculate the film coefficient for air at 1atm and 32℉ flowing through a pipe (4in ID) at 10
fps.

From table 4-1 Eq A

0.32²> Q.z
ℎ=
• Q.By

0.32410:Q.z
ℎ= = 2.6572
V Q.By
ÔJBÕ

4-14 Determine U for steel-tube air preheater(flue gas inside the tube and air on the outside) with
staggered 3in tubes(more than five rows deep), 10ft long and placed 6in on centers and 0.18 in thick.
The tubes are located in an area (perpendicular to the air flow) 6x10 ft and the gas flow is
250000lb/hr at an average temperature of 230℉. The actual gas velocity inside the tube is 20fps.

4-J − -V :
)= ¨Æ
J “” J
W ¨…
W
¡O½O Bƒ¢„ ¡Ì½Ì

) = £34-J − -V :
) 4-J − -V:
= £3 =
4-J − -V : J “”
¨Æ
J
W ¨…
W
¡O¬Oƒ„ Bƒ¢„ ¡Ì¬Ìƒ„

13
9+-3 = 3> = f•>g
Ú ß
1 Ù 1 Þ
£¦ = Ù ¨Æ Þ
f•>g J ¬Ì ¬Ì“” J
Ù Û W ¨…
W ÜÞ
؃¬Ì„ ¡O¬O B¢ ¡Ì Ý

Ú ß
Ù 1 Þ
£¦ = Ù ¨Æ Þ
¬Ì“”
ÙÛ ¬Ì W ¨… J
W ÜÞ
Ø ¡O¬O B¢ ¡Ì Ý
From table 4-1 use Eq A
0.32²> Q.z
ℎ=
• Q.By

? = 20150
9H
à,019>× = 250000
ℎ.
-6 = 530℉
• = 36/
à = ²Ì áÌ = ²á
â² = ;b-
â> â
²> Ç È = ²Ç È
b>À> bÀ

²À> 20432 W 460:

²> = = = 9.9393150
À 530 W 460

0.3249.9393:Q.z |-8
ℎ6 = = 2.8415
U Q.By 1- B − ℎ. − ℉
ÔJBÕ

*For Steel
|-8
= = 25
1- − ℎ. − ℉

*For outside film

From table 4-1 Eq F

²>Q.Óã
ℎ> = 0.91 Q.UJ
•
2,H
•= → .+7287-
,WH

Take b=2ft
JQ
246: Ô Õ
y
•= = 31-
6W2

14
 à
²Ì =
áÌ

; â 14.74144: 9H
áÌ = = = = 0.08066 U
? bÀ 53.34432 W 460: 1-

420 9H
áÌ = = 0.08066 U
5207 1-

“Ñ J¡d
230000 × 575 9H
¡d UÓQQä•Ë
à= = 5.3240 =
61- × 21- 108 1- B − 0

5.3240 1-
²> = = 66.00584215
0.08066 0

0.91466:Q.Óã
ℎ> = = 25.1864
U Q.UJ
ÔJBÕ

•> = 3 W 240.18: = 3.366/

1
£> = š.š.– š.š– = 2.3015
U.UÓ “” J
W ™‹ š
W
U×B.zVJy B×By By.JzÓV

4-20 An economizer receives water at 210℉ and gas at 635℉ for the water and 470℉ for the gas
with counterflow. The 2in OD steel tubes are staggered. For the gas, the mass flow is 9000lb/ft2-hr
and the water velocity is 7.5fps. The metal is 0.109in thick. What is the value of Uo?

1
£¦ = §¨
J ¦¬“” ¦¬
W ©¨
W
¡§ B¢ ¡… 4-¬:
Solving for Ä
From table 4-1 use Eq F
²>Q.Óã
ℎ> = 0.91 Q.UJ
•
à
²Ì =
áÌ
9H 1ℎ. 9H
à = 9000 × = 2.5 B
1- B
− ℎ. 36000+7 1- − 0+7
*assume å of gas is the same as å of air at standard
9H
áÌ = 0.08 U
1-
2.5
²Ì = = 31.25150
0.08
431.25:Q.Óã |-8
ℎ> = 0.91 Q.UJ = 17.04962 B
B 1- − ℎ. − ℉
ÔJBÕ

15
 æMç†NM
k for steel is 25
NM ‹ †¡d†℉
solving for R
From table 4-1 eqG

ℎ6 = 163² Q.zy 41 W 0.0104-:

210 W 280
-= = 245
2

ℎ6 = 16347.5:Q.zy 41 W 0.01044245:: = 3206.072134

2 − 240.109:
•6 = = 0.14851-
12

1 |-8
£¦ = ‹ = 16.8387
‹
“” ™‹ 1- B − ℎ. − ℉
J B
W ™‹ .™—³˜
W
Jt.QVã B×By J.tzB×UBQÓ

4-26 Considering radiant energy only, would it be better to paint a radiator in home black
(É = 0.9) or paint it with aluminum paint (É = 0.3)? For temperature of 145℉ and 70℉,
estimate the percentage of change in radiant energy based on black paint.
145 W 460 V 70 W 460 V
) = 0.17440.9: ®Ç È −Ç È ¯
100 100
) = 86.2388 → H+--+.

145 W 460 V 70 W 460 V

) = 0.17440.3: ®Ç È −Ç È ¯
100 100
) = 28.7463
86.23 − 28.74
%7ℎ,/è+ = × 100% = 66.6667%
86.23

4-30 Steam enters a 100ft section of bare 4in schedule 40 pipe saturated at 25 psia. Room
temp is 80℉, and the steam velocity is 6000fpm. What is the quality of the steam leaving the
pipe(neglect pressure drop)?

From steam table

Tsat @ 25psia=240.08℉

Temp difference from surface air

240.08-80=160.08

From Plate 1 page 675

Do=4.5
Di=4.026

From Fig 4-17

16
 |-8
ℎËd = 2.9
1- B − ℎ. − ℉
4.5 |-8
) = 2.9 Çf × 100È 4240.08 − 80: = 54691.09403
12 ℎ.
To solve for x convert q into Btu/lb

NM š
From steam table @ 25psia take é = 16.3
“Ñ

54691 × 16.3 |-8

∆ℎ = = 28.01085641
ƒ V.QBÓB 9H
× × 6000 × 60
V JB
From steam table @ 25psi
ℎ1 = 208.52
ℎè = 1160.7
ℎ1è = 952.2

∆ℎ = ℎè − ℎ
ℎ = 1160.7 − 28.01 = 1132.689144
1132.68 − 208.52
<= = 0.9706 → .>8/2>11-> 4 2+76;,959,7+0
952.2

Since é is only an assumption, check if the assumption is correct

? = ?1 W <?1è
From steam table @25 psi
?1 = 0.016922
?è = 16.306
?1è = 16.289078
? = 0.016922 W 0.9706416.289078: = 15.82710111
?•ääçëì ≠ ?ËÌëì
So recalculate until é^Ã߶î = é`Ķî
28.01 × 15.82
∆ℎ = = 13.92997487
ƒ V.QBÓB
× × 6000 × 60
V JB
ℎ = 1160.7 − 13.9 = 1146.77
1146.77 − 208.52
<= = 0.9853
952.2

→ ïÄm'RmŸðR'ðn^'RÄm
Value of x is between 0.97 − 0.985

Another solution is by using radiation alone

4-35 One utility company specifies 2in of high temperature insulation(diatomaceous

earth) and 2in of 85% magnesia insulation for a working temperature of 800℉ on all pipes
6in or larger. Estimate the efficiency of this insulation for 10in schedule 160 pipe. Room
temperature is 70℉.

From plate 1
10in schedule 160

17
Do=10.75in

From Fig 4-17

Temp difference = 800-70=730
ℎ7. = 6.7

) = ℎ7.34- − -1:
10.75 |-8
) = 6 Xf × × 1Y 4800 − 70: = 13764.95366
12 ℎ. − 1-

*using the formula above neglect the effect of film coefficient inside and wall of the pipe. It
was assumed that the temperature inside the pipe is the same as the outside surface
temperature of the pipe for bare pipe.

Neglect the effects of pipe and inside film:

Ti=T2=800

*For diatomaceous earth

¬
)9/ š
¬‹
-B − -U = →1
2fL+g

*For 85% magnesia

¬
)9/ ¬—
š
-U − -V = →2
2fL;g

*For outside film

)
-V − -N = →3
ℎËd f•V g
Note: no 'ñ because you are using `n

18
Combining 1,2 and 3
¬š ¬—
) 9/ ¬‹ 9/ ¬š 2
-B − -N = q W W r
2fg L+ L; ℎËd •V

2fg4-B − -N :
)= ¨ ¨
“” š “” — B
¨‹ ¨š
® W W ¯
¢• ¢ë ¡ÍŠ ¬—
From Fig 4-1b
For diatomaceaous earth at 550℉ mean temperature
Note 550 is a guess
|-81-
L7 = 0.06
ℎ. − 1- B − ℉
From Fig 4-17
For •V = 10.75 W 242 W 2: = 18.75"

Assume surface temp= 100℉

|-81-
ℎËd = 7.8 B
1- − ℎ. − ℉
2f41:4800 − 70:
) = ™—.´˜ ™³.´˜ = 392.1447376
“” “” B
® Q.QÓ W Q.QVB W
™•.´˜ ™—.´˜
™³.´˜ ¯
J.zÔ Õ
™‹

Check the assumed temperature

JV.ty
3929/
JQ.ty
-B − -U = = 329.05
2f40.06:

-U = 800 − 329.05 = 470.9471℉

Jz.ty
3929/
JV.By
-U − -V = = 114.3817
2f40.042:

392
-V − -N = Jz.ty = 69.99℉
1.8f
JB

*diatomoceous earth
800 W 470.94
= = 635
2
Assumed value 550
Adjust
Ke=0.062

*85% magnesia

19
 470.94 W 114.3817
= = 292
2
Assumed value 400
Adjust
Km=0.04

*for `n
Temp difference = 144-70 = 44
ℎ7. = 1.8

2f41:4800 − 70:
)= ™—.´˜ ™³.´˜ = 388.3075881
“” “” B
® Q.QÓB W
™•.´˜
Q.QVB
™—.´˜
W ™³.´˜ ¯
J.zÔ Õ
™‹

Insulation efficiency
388.30
=1− = 97.179%
13764.95366

20
 CHAPTER 8
HEAT EXCHANGERS

General
• Steam exhausted to atmosphere
-Acts as a condenser
• Condenser reduces make-up water
• Make-up cannot be reduced to zero because there are always some losses
from traps boiler blowdown,leaks at the packing glands, and contaminated
returns from steam heating systems or oil consuming equipment.
• Condenser lowers exhaust pressure thus increasing efficiency
• Feedwater heater raises the temperature of the condensed steam before
inducting it into boiler
• Feedwater heater prevents contraction of metals in boiler

CONDENSERS

Barometric and low-level jet Condensers

Methods of condensing
1. Mixing or direct contact
2. Surface

Surface Condenser
-eliminates contamination of feed water

Condenser Calculations

ó = ±%µ¶

µi − µZ 'i − 'Z
µ¶ = µi
= 'Ã^'ô 'Z
lm lm
µZ 'Ã^' †'i

£ = ū4¾-:4¾;:4¾7:4¾5:
ū → ¾6è 8 − 9
¾- → -+;57>..+7-6>/1,7->.
¾; → -8H+;,-+.6,9,/2-ℎ67=/+007>..+7-6>/1,7->.
¾7 → 79+,/96/+001,7->.
¾5 → 5.6;+;>?+.1,7->.0
1 → -8.H6/+
0.75 → 0-+,;+/è6/+

*cleanliness factor
0.85 → 79+,/>.7ℎ9>.6/,-+2
0.95 → è>>2×,-+.7>/26-6>/

Example 1

21
Design a surface condenser for a turbine that exhausts 50000 lb/hr of steam at 2in Hg abs
with circulating water entering at 80℉. Use an 8 degree terminal difference,7fps
velocity,3/4in 18 BWG tubes, and a cleanliness factor of 0.85.

93.1 − 80
ºë = JQJ.J†zQ = 13.5075℉
9/
z
From Fig8-9 ū = žZõ
Temperature correction factor = 1.05
Eq 8-3
£ = ū4¾-:4¾;:4¾7:4¾5:
¾; = 1
¾7 = 0.85
¾5 = 1 → -8.H6/+
|-8
£ = 71341.05:41:40.85:41: = 636.3525
1- B − ℎ. − ℉

Solving for the surface area of condenser

) = £3º

From page 356

_'Ÿ
! = œñ• → mÄm nð ð^' 'Ÿn_Rmð
l_
_'Ÿ
! = Z••• → ðmöRmð ^îîlR`^'RÄm
l_
→ nð ð^'
) 950 × 50000
3= = = 5526.12721- B
£º 636 × 13.54

*find for the number of tubes

Compute for the volume/mass of water neeeded to extract the”q”.

Using
ó = ¶ïî∆¸ → ^îîlR`^_lð SÄn ÷^'ðn ÷R' lÄ÷ 'ð¶îðn^'Ÿnð ^m& mð^n 'Ä ø^'¶

|-8
ù5 = 1
9H − ℉

∆À = 93.1 − 80

22
 ú 50000 × 950 9H
;= = = 3,625,954.198 ×,-+.
ù5∆À 93.1 × 80 ℎ.

l_
Using ›i. [ density of water
S'õ
Compute for the volume flow rate
; 3,625,954.198 1- U
?= = = 58108.2404
á 62.4 ℎ.

S' õ
It is stated that velocity of water is ž and in 18BWG Di=0.652in from page 353
Ãð` [

For this size of tube and velocity the maximum volume flowrate for 1 tube is:

f 0.652 B 1- U
? = 34?+9: = Ç È 47: = 0.0162 5+. -8H+
4 12 0

S'õ
To accommodate a total volume flowrate of 58108.2404 increase the number of so:
n
58108.2404
= 994.53-8H+0 ≈ 995-8H+0
58.428
*find for the tube length
The needed surface is 5526.1272S'i
3 = f•Ì g4Ö-:

0.75
5526.1272 = f Ç È g4995:
12

g = 28.581-
Now refer to table 8-2 page 354 for a surface area of 3000-6000S'i the approximate
recommended L is 14-20. So the L computed is out of range. Make the tube 2pass, dividing
the length in to two, thus iý. ñý ÷ i = Z[. Z[iœS'

*Find for the friction loss

J
A condenser of this size would have 6/ thick tube sheets so the actual tube length could be
B
14.21-

From Fig 8-11, the friction loss in the condenser would be

2414.2:40.4: W 42:41.41: = 14.181-

Problem 8-4
A surface condenser is to operate under the following conditions: 150,000kw turbine exhaust
steam rate 8lb per kwhr, 1in Hg abs, single-pass, ¾ in no. 18 BWG Admiralty tubes, 50℉ inlet
water temp 8fps velocity, 2ft friction drop in the inlet tunnel, 1ft for the outlet tunnel, 3ft
drop in the inlet pipe, 1.5ft in the outlet pipe, top of the outlet pipe 18ft above river level,
85% cleanliness, 15°terminal difference, 80% circulating pump efficiency.
Find: a)outlet temp of circulating water
b)surface
c)gpm of circulating water

23
 d)number of tubes in condenser
e)effective tube length
J
f)total weight of tubes in condenser ,allowing 1 6/ tube sheet thickness
V
g)friction drop through condenser
h)total dynamic head for circulating pump
i) horsepower of circulating pump motor
solution
14.7
16/Aè × = 0.5506,
29.92
Tsat @0.5 psi=79.56℉

ºJ
ºB

A) ¸i = 79.56 − 15 = 64.56
4» †» : Bã.yÓ†Jy
B) k·¸¹ = ‹ !‹™ = ‹".˜– = 21.4631℉
“” “”
!™ ™˜

For ¾ in No. 18 BWG tube 8fps water velocity

# = 7 $?
# = 270$8 = 763.6753

with 50℉ inlet water, from Fig 8-9

¾- = 0.84
¾; = 1
¾7 = 0.85
¾5 = 1

£ = 7634. 84:41:4. 85:41: = 545.2641811

|-8
ú = 95048:4150000: = 1140000000
ℎ.
ú = £3ºë

1140000000
3= = 97410.181751- B
545 × 21.4631

C) Gpm of circulating water

ú 1.14 × 10ã 9H
;= = = 78296703.3
ù5∆À 1464.56 − 50: ℎ.

9H 11- U 7.481è,9 1ℎ.

78296703.3 × × U
× = 156447.0185è5;
ℎ. 62.49H 11- 60;6/

24
D) Number of tubes
From table 8.1 for ¾ in 18 BWG tube Di=0.652in
f 652 B 1- B
36 = Ç. È = 2.3185 × 10†U
4 12 -8H+

Total volume of water needed

1 1 1- U
= 78296703.3 Ç È×Ç È = 348.5430168
62.4 3600 0

Volume flow rate per tube

f 652 B 1- U
= Ç. È × 8 = 0.01854 5+. -8H+
4 12 0

Number of tubes
348.54
= = 18790.73718 ≈ 18791-8H+0
0.01854

E) The total outside surface needed is: 97410.187911- B as computed for a ¾ in tube the
Q.ty J
outside are per ft is:= f Ô Õ 41: = f
JB JÓ

For all tubes

1
= f418791: = 3689.604
16

Length of tubes
97410
= = 26.401254951-
3689

Consulting table 8-2 for a surface are over 20000 1- B the approximate table length is
22-30ft

The actual tube length with 1 ¼ “ tube thickness

1.25
= 26.40125 W 2 Ç È = 26.609588291-
12

From table 8-1 for ¾ in 18BWG the weight of tube per linear ft is: 0.417 lb/ft

Weight of total tubes

= 26.64. 417:418791: = 208508.6626 9H

F) Actual tube length as computed above: 26.6095ft

G) Friction drop through condenser from Fig 8-11 for ¾ in 18 BWG tube and 8fps
1-AB0
-8H+ 1.67-6>/ 9>00 = 0.52 5+. 5,00
1-
NM%‹ Q
Pressure loss in water box= 1.74 ì•ää
Friction Drop through condenser

25
 4 6095: W 1.74=15.57694 ft H20
= 0.52426.6095

H) Total dynamic head for circulating pump

= 15.57 W 2 W 1 W 3 W 1.5 = 23.07694 ft H20

Assuming 10% of friction loss in the pipe top outlet = 0.10(18ft)=1.8

= 24.87694 1- AB •

82
•@/,;67 ℎ+,2
+,2 = 24.87 W = 25.87071- ℎB •
2 × 32.2

I: Horsepower
1 25.87
×,-+. A5 = ú)ℎ = 78296703.3 Ç È × = 1023.026
026 ℎB • A5
60 33000
1023
;>->. A5 = = 1278.7833ℎ5
0.8

FEEDWATER HEATERS

8-8 Surface Type of Feedwater Heater

Difference (condenser and heater)

1. Heater – temperature
2. Pressure
3. Strength of parts

8-9 heat Balance calculation for surface heaters

'4ℎ0: W (4ℎ6: = '44ℎ2: W (4ℎ2:

(4ℎ2 − ℎ1:
'=
ℎ0 − ℎ2

8-10 Surface Calculations

26
 *Rl¶ 'ð¶îðn^'Ÿnð = -0,- − 40.8 g¿À•:

EXAMPLE 8-4
A 12650kw turbine generator may have either three or four stages of feedwater heating. If the unit
will operate at the load for 400
4000hr/yr.
0hr/yr. calculate the return on the investment for the fourth heater
for the following data; 5/8 in no.16 BWG no 16 BWG 80/20 Cu Ni tubes, water temperature of 275 ℉
Cu-Ni
entering heater and 350℉ leaving, improvement in heat rate is 175 Btu per kwhr, heater costs
$14.00 per sq ft surface plus $6000 for installation and piping 5F TD, 120000 lb per hr of water, fuel
cost 31cents per 10JÓ , pump efficiency is 69% (wire to water), additional piping pre
pressure loss is 4psi,
cold water velocity in the tubes to be 8fps, plant heat rate of 125000 Btu per kwhr with four heaters.

ty
ºë = ³• = 27
27.05℉
+,
˜
|-8
ℎN ,- 350 ¾ = 321.6
9H
|-8
ℎN ,- 275 ¾ = 243.9
9H
|-8
ú = (∆ℎ = 1200004321.6 − 243.9: = 9324000
ℎ.

¾69; -+;5 = 355 − 0.8427.05: = 333.36℉

Above 250℉ use curve for 250
Fig 8-23
£ = 910 × 0
0.88 = 800.8

9324000
3= = 430.43832321- B
800.8 × 27.05

No. of Tubes:
; 120000 1- U
?>9 = = = 0.5341880342
á 6262.4 × 3600 0

f 0.495 B 1- U
?>9 5+. -8H+ = Ç È 48: = 0.01069 5+. -8H+
4 12 0

0.53
/>. >1 -8H+0 = = 49.96 ≈ 50 -8H+0 5+. 5,00
0.01
Effective length

27
 Surface area of 50 tubes per 1ft
0.625 1- B
= fÇ È 41:450: = 8.18123
12 -8H+

430.43
g= = 26.3064 1-
8.18 × 2

26.3064
g= = 13.1532 1-41>8. 5,00:
2
Friction loss from fig 8-24
4¾1:4¾2:4g W 5.52:Ö
∆5 =
2J.By
F1=0.135

Average water temp

= 355 − 27.05 = 327.35
¾2 = 0.75

4. 135:4. 75:o13.2 W 5.540.495:p4

∆5 = = 15.4225506
0. 495J.By

∆5 = 15.42 W 4 = 19.4225

120000
= 266è5;
500 × 0.903

0.7464266:419.4:
;>->. 6/58- = = 3.25=×
0.6941714:

3.25412500 − 175:44000:40.31:
,//8,9 cos >1 ,226-6>/,9 5>×+. = = $49.80
10Ó

175412650:44000:40.31:
,//8,9 0,?6/è0 = = 2750
10Ó

/+- .+-8./ = 2750 − 49.80 = 2700

7>0- >1 ℎ+,-+. = 431414: W 6000 = 12030

2700
b•‘ = = 22.4%
12030

8-6 Design a surface condenser for the following conditions: 25000kw turbine, exhaust steam
rate 8lb per kwhr, two pass, 7/8 in no. 18 BWG tubes, 7fps water velocity, 8-degree terminal
difference, 2-ft friction drop in inlet tunnel,1 ft in outlet tunnel, 3ft in inlet pipe,1.5 ft in outlet pipe,
outlet pipe 24ft above river level, 86% circulating-pump efficiency.
Find: A) outlet temperature of circulating water
B) gallons per minute of circulating water
C) surface area

28
 D) number of tubes in condenser
E) total weight of tubes, assuming tube sheet thickness of 1in.
F) friction drop through condenser
G) total dynamic head on circulating pump
H) horsepower of circulating-pump motor.

A) ¸i = ý• − ý = ži℉
B) Heat released by steam
|-8
ú = 8425000:4950: = 1.9 × 10z
ℎ.
Energy released by steam
ú = ;ù5∆À
Assume water temp(inlet)=50℉

1.9 × 10z 9H
;= = 8636363.636 >1 .+76.789,-6/è ×,-+.
72 − 50 ℎ.

Converting to GPM using the mean water temp and steam table to get the
specific volume
1
= 450 W 72: = 61℉
2
1.>; 0-+,; -,H+940,-8.,-+2 61℉:

1- U
? = 0.0160345
9H
Therefore the volume flow rate of water is:
7.481
? = 8636363.63640.016035: Ç È = 17266.65807àâ¿
60

C) Surface area
ú = £3ºë
£ = #4¾-:4¾;:4¾7:4¾5:

# = c$v = 263$7 = 695.8325948

assumed
£ = 69540.84:41:40.85:41: = 469.8245

72 − 75
ºë = zQ†yQ = 16.6445℉
9/ zQ†tB

1.9 × 10z
3= = 22976.25157 1- B
496416.64:

D) No. of tubes in the condenser

29
 From table 8-1, 7/8 in no. 18 BWG tube, the flow rate of this tube with a
velocity of 1fps is 1.48gpm
17266.11966 -8H+0
>. >1 -8H+0 = = 1667
1.48 × 7 5,00

For 2 pass: total no. of tubes

= 166742: = 3334 -8H+0
S'i
From table 8-1 for 7/8 in OD outside surface per linear ft = 0.2297
S'
Therefore:
229766
+11+7-6?+ 9+/è-ℎ >1 -8H+ = = 60.0041-
166740.2297:
For 2 passes
= 30.0021-

Providing for tube sheet thickness

1
,7-8,9 9+/è-ℎ = 30.002 W 2 Ç È = 30.161-
12
From page 354:
Since there is a cost penalty for excess length the assumed values for steam
exhaust pressure and inlet water temperature should be reconsidered.

Taking inlet water temperature to be 60℉ instead of 50℉

From Fig 8-9, it will be 0.93
Thus
# = 263$740.93:41:4. 85:41: = 550.0556662
Still using 1inHg abs steam exhaust pressure:
-B = -0,- − º = 80 − 8 = 72℉
Then

72 − 60
ºë = zQ†ÓQ = 13.096℉
9/
zQ†tB

1.9 × 10z
3= = 26375.39704
550413.096:

ú 1.9 × 10z 9H
×,-+. 19>× .,-+ = = = 15833333.33
ù5∆À 72 − 60 ℎ.

1
;+,/ ×,-+. -+;5 = 472 W 60: = 66℉
2

?1 = 0.016043

² = 31671.33301è5;

31671
/>. >1 -8H+0 = = 3058
1.48 × 7

30