CET33AT Lab Manual

FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT
DEPARTMENT OF CHEMICAL AND METELLURGICAL ENGINEERING
STUDENT LABORATORY
GUIDE
NAME OF COURSE:
CHEMICAL ENGINEERING TECHNOLOGY( IIIA)
NQF
LEVEL
NQF
CREDITS
QUALIFICATION & SAQA ID

Diploma
In
ENGINEERING
SAQA ID No.:
CHEMICAL
COMPILED BY (Molelekoa Mosesane)

(2015)
COURSE CODE
(CET33AT)
COPYRIGHT : Tshwane University of Technology

Private Bag X680
PRETORIA
0001
All rights reserved. Apart from any reasonable quotations for the purposes
of research criticism or review as permitted under the Copyright Act, no part
of this book may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy and recording, without
permission in writing from the publisher.
Printed and distributed by :

FACULTY OF ENGINEERING AND
BUILT ENVIRONMENT
Tshwane University of Technology
ORGANISATIONAL COMPONENT CONTENTS:

1.......................................................................................................................................Welcome
......................................................................................................................................................6
2...................................................................................................................LABORATORY Staff
......................................................................................................................................................7
2.1
Contact Details.............................................................................................................8
2.2
Staff availability............................................................................................................8
3. ...............................................................Requirements, resources and recommended material.

......................................................................................................................................................9
3.1
Requirements for the course.......................................................................................10
4. ..........................................................................................................................Code of conduct
....................................................................................................................................................12
Safety..........................................................................................................................................12
B. Laboratory Format and Procedures.................................................................................12
4.1
Attendance..................................................................................................................15
4.2
LABORATORY, HEALTH & SAFETY RULES AND REGULATIONS.................16
4.3
Responsibilities of students........................................................................................16
5. Assessment..............................................................................................................................17
5.1
Assessment methods and criteria...............................................................................17
5.2
Assessment rules.........................................................................................................17
5.3
Marking system..........................................................................................................17
5.4
predicate/Year mark....................................................................................................18
5.5
Moderation..................................................................................................................19
5.6
Promotion requirements.............................................................................................20
6. ......................................................................................laboratory course content and schedule

....................................................................................................................................................20
6.1
schedule of laboratory sessions and assignments.......................................................20
6.2
Learning outcomes and assessment criteria................................................................21
6.3
Generic outcomes and critical cross-field outcomes..................................................22
7. Glossary of terms....................................................................................................................22
7.1.Assessment Records.............................................................................................................22
7.2
Example of a practical report......................................................................................23
Guidelines for the Preparation of Written Reports...............................................................23

A. Apparatus............................................................................................................................24
B. Procedure.............................................................................................................................24
Unit study for the study of load losses
25
Test bench pumps
31
Heat exchanger pilot plant......................................................................................................39

Concentric heat exchanger......................................................................................................49
9.
ExampleS of mark sheets used during various assessments.......................................56
SECTION
ORGANISATIONAL COMPONENT
1. WELCOME
Welcome to laboratory session of Chemical Engineering Technology IIIA. This part of the
course provides an introduction and represents advanced knowledge in unity operation and is
offered via experimental work, problem-based work or project-based work over 8 weeks. The
course is structured in such a way as to master theoretical concepts and principles and various
practical skills to provide a sound foundation for the study of Load Losses, Test bench pumps
and Heat transfer to complement the major courses in the qualification and pave the way for
more advanced learning in B-Tech in Chemical engineering. We trust you will enjoy the
course, and find it interesting and informative.
2. LABORATORY STAFF
2.1
CONTACT DETAILS
NAME
CAMPUS
ROOM NO
TEL NO AND EMAIL
Mr M.S
Ranyaoa
Pretoria
B3 R 707
(012) 382 3514
Mr M.
Mosesane
Pretoria
2.2
CONSULTATI
ON TIME
ACADEMIC
FUNCTION
Lecturer
ranyaoams@tut.
ac.za
B2 R127
9012) 382 4655
9h00
16h00
Technologist
STAFF AVAILABILITY
If, after attending class and making every effort from your side to master content, you still have
problems with understanding key concepts or principles or their application, lecturers are
available for consultation.
To consult your lecturer, make an appointment by calling his office or see/ call the secretary at
(012) 382 3550/3514 for an appointment.
To consult your technologist, make an appointment by calling his office at 012 382 4655 or
call the secretary at (012) 382 3514.
3. REQUIREMENTS, RESOURCES AND RECOMMENDED MATERIAL.

3.1
3.1.1
REQUIREMENTS FOR THE COURSE

PRESCRIBED RESOURCES
The following tables indicate what literature and other resources are essential for successful
completion of this course. You are strongly advised to acquire all the prescribed resources.
PRESCRIBED RESOURCES
CATEGORY
DESCRIPTION
WHERE TO FIND
CALCULATOR
Scientific
Bookstore
COMPUTER
HARDWARE
SOFTWARE
Soshanguve,
Arcadia
Pretoria campuses
and
Laboratory Journal/Record Book Bookstore

( Not a page or exam pad )
COST
LEVY
EQUIPMEN
T
Building 2 lab. 127

Load Losses Study Unit, Test Bench Pilot Plant and Heat
Exchanger Pilot Plant with Three Exchangers.
COMPONENTS
3.1.2
RECOMMENDED RESOURCES
The following recommend resources will enhance your understanding and knowledge in this
course, and you are encouraged to use the following additional resources.
RECOMMENDED RESOURCES
CATEGORY
AUTHOR
NAME
BOOKS
Library books
MANUALS
Laboratory
manual
Online
GUIDES
Study guides
Online
PUBLISHER
ISBN NO
RECOMMENDED ELECTRONIC MATERIAL & WEBSITES

VIDEO
CD
DVD
WEBSITES
myTUTor
tut4life.tut.ac.za
4. CODE OF CONDUCT
Please take note of the following regulations. These regulations are in addition to the standard
rules and regulations as determined by the TUT. Please familiarise yourself with the TUT rules
and regulations as set out in the student diaries received on registration.
Safety
Laboratory safety is the top priority and this requires all people in the lab to be observing safe
practices at all times!
Safety glasses must always be worn by everyone in the laboratory.
Make sure you understand how the experimental apparatus works and what all
of the adjustments done before you attempt to operate it.

Be sure you have asked, and received an answer, from the Technician
about any possible hazards related to your experiment before attempting to operate it.
Care must be used in the handling of chemicals to avoid spills and to avoid contact with the
skin.
B. Laboratory Format and Procedures
1. Organization of Student Groups and Laboratory Projects
Students will organize into groups of five persons. Each group is to perform three projects
during the semester. (A roster of the groups and a schedule of projects will be supplied
separately.)
A group leader, who is in charge of directing the work for the lab, should be selected
by, and from among, the members of the group. (This responsibility should rotate
among the members.) All group members must be prepared for the laboratory and
contribute equally to the laboratory work and preparation of the reports. However, the
group leader is in charge of assigning and coordinating tasks for the laboratory period
and maintaining the group notebook. He or she is ultimately responsible for making
sure that everything is done to ensure a successful experiment.
2. Laboratory Session 1
At the beginning of the first session for a given experiment, a paragraph
describing the experimental plan and procedure should be submitted to the
Technician who is in charge at that time. A discussion between the Technician and
the students will take place to ensure that students have an accurate plan of action.
3. Laboratory Session 2
The Technical report should be submitted to the Technician in charge of the experiment. A
summary discussion of the report with the instructor will be conducted in the laboratory.
4. Session 3
The laboratory will be open to gather additional data if needed. The lecturer will be available
for consultations during the first hour of the laboratory period. During this session
examination of the experimental apparatus for the next assigned project should be performed
by each group.
5. Final Technical Report .
The final Technical report is due at the beginning of the next scheduled laboratory period
following Session 3. There are no exceptions to this deadline. The reports are to be
submitted to one of the department secretaries in the Chemical Engineering office or to the
Technician. During the week following the day on which the final report was submitted, the
group should schedule a meeting with the lecturer for the discussion of the written report. Each
member of the group should be prepared to defend and/or discuss any part of the final report.
6. Laboratory Notebook
Part of the purpose of the chemical engineering laboratories is to learn good laboratory and
research practices. An important aspect of this is safety. Another important aspect is recordkeeping and documentation. In industry you will find that all experiments have to be carefully
recorded in an official laboratory notebook and signed by the investigator on a daily basis. To
help foster these professional practices, each group is required to keep a laboratory notebook
documenting the group's work. In the notebook should be kept a neat, labeled and dated record
of all work associated with the experiment, including a copy of the precis, all raw data, the
settings on the experimental controls, any problems encountered in the experiment and what
was done to fix them and why, all calculations, a copy of your progress report, etc. The
laboratory notebooks will be handed in at the end of the semester and will contribute to the
laboratory participation portion of your grade.
7. Student Responsibilities in the Laboratory
Condition of Working Area. Students are responsible for the condition of their working area
at the end of each laboratory period.
All power to the equipment and instruments should be turned off,

and steam and cooling water flows should be shut off.
Glassware used should be cleaned and dried.
Any equipment or instrumentation malfunctions should be
reported promptly to the Technician or assistants.
Checkout before Leaving Laboratory. The students must have their notebooks initialed by a
Technician prior to leaving at the end of the laboratory period. At that time the Technician will
check the working area and take information about any equipment or instrumentation
problems.
8. Grading/Marking
Report grading is done by the lecturers who are in charge of a given experiment. This grade
will be based on the written report, the oral defense and other pertinent factors (e.g., if you are
totally unprepared to do an experiment, you will be docked.) Grades for this course will be
determined by the grades on the three experiments as well as your laboratory participation.
The laboratory participation portion of your grade in will include how well you followed
laboratory safety guidelines (did you wear safety glasses at all times in the lab? did you follow
the special safety precautions required for each experiment?), attendance, tardiness,
participation, professionalism, how effective a group leader you were, and the quality of your
laboratory notebook. Both laboratory instructors and teaching assistants will contribute
towards this portion of your grade.
4.1
ATTENDANCE
Regular attendance of the chemical engineering technology (IIIA) lectures is of primary

importance. It is the learners responsibility to sign the register each week. A minimum
attendance of 75% is mandatory for all courses including practical In a 30 week year, 8 classes
that have not been attended and for which you have not furnished a valid doctors letter or
other proof of extenuating circumstances, amounts to 25% absenteeism. This level of
absenteeism will lead to exclusion from the final moderation at the end of the year, which
means that you will fail the course and will have to repeat it the following year.
4.2
LABORATORY, HEALTH & SAFETY RULES AND REGULATIONS
4.2.1.
LABORATORY RULES
BASIC RULES
4.3
Always wear a laboratory coat in the laboratory.
Do not wear open shoes in the laboratory.
Do not eat or drink in the laboratory.
No horse-playing in the laboratory.
Always ask the technician if you are not sure of anything.

RESPONSIBILITIES OF STUDENTS
It is your responsibility to make a success of learning in this course. To this end you are
encouraged to attend practical class, write practical report and hand in your
assignments/projects on the set due dates.
SECTION
LEARNING COMPONENT
5. ASSESSMENT
5.1
ASSESSMENT METHODS AND CRITERIA
Assessment of this laboratory course will include experimental work, problem-based work,
Project-based works and assignments, report writing. The purpose of assessment is to
determine whether you have achieved the learning outcomes. The various assessment methods
therefore will focus on criteria that will enable the lecturer(s) to determine whether you have
achieved the learning outcomes and mastered the required skills. The assessment criteria
relevant to each learning outcome are detailed in section 2.2.
5.2
ASSESSMENT RULES
The general rules of TUT regarding assessment apply. You are advised to familiarise yourself
with these rules, as they are applied stringently.
5.3
MARKING SYSTEM
SUBJECT
MAX
MA
RK
1.
TITLE PAGE
2.
ABSTRACT
3.
INTRODUCTION
4.
THEORETICAL
BACKGROUND
ACTUAL
MARK
5.
PROCEDURE
6.
RESULTS
7.
DISCUSSION OF RESULTS
10
8.
CONCLUSION
AND
RECOMMENDATIO
NS
9.
LITERATURE CITED
10.
NOMENCLATURE
11.
ORGANIZATION
NEATNESS
AND
Appendix
A1
Raw Data
A2
Data analysis and Sample

Calculations
10
TOTAL
50
5.4
PREDICATE/YEAR MARK
The practical mark will contribute 50% to the year mark

Predicate marks are put on the faculty notice boards. If you have queries about your mark,
you must immediately consult your course lecturer , before predicate day. Once the
predicate mark is entered on TUTs mainframe computer, the mark cannot be changed.
1.5
MODERATION
The lecturer of the subject will be responsible to moderate all practical report.
1.6
PROMOTION REQUIREMENTS
The leaner has to obtain the minimum of 50% in the practical report in order to pass.
6. LABORATORY COURSE CONTENT AND SCHEDULE
This course comprises of an experimental component, problem-based component and a
project-based component. Your mastery of the required skills is assessed at regular intervals.
More importantly, the application of theory is assessed through problem-based- or projectbased assignments or projects.
The following outline provides an overview of the content to be covered in this course and the
ways in which your progress will be assessed.
6.1
SCHEDULE OF LABORATORY SESSIONS AND ASSIGNMENTS
EXPERIME
NTAL/
DURATION
THEME
PROBLEMBASED/
PROJECTBASED
Week 1-4
PRESSURE
Load Losses
(Learning Outcome 1)
Obtain the relationship between the

straight pipe head loss and the
volume flow rate by plotting log hL
against log Q.
Plot friction factor data versus
Reynolds number for the straight
pipe. Also obtain relationship
between F and Ren ; by plotting log
DROP
PIPING
SYSTEMS
IN
COMPLE
TION
DATE*
f against log Re. Comment on your

results by comparing with the
literature given equation.
Obtain the value for K for the gate
valve when it is fully opened and
compare with literature.
Discuss head losses in 90 Mitre
and standard elbow bend.
Obtain the value for K for globe
valve when it is fully opened and
compare with literature.
Determine the discharge coefficient
used in the characterization of the
flow meters (orifice and venturi)
Compare the measured and the
literature discharge coefficients.
Week 5-8
TEST
TEST BENCH
BENCH
(Learning Outcomes 2 )
It is expected that the students will be able
to
Week 9- 12
Calculate system head

requirements.
Determine head, pump efficiency,
and pump horsepower from a
typical pump curve.
Compute NPSH required by the
pump.
Describe how to modify system to
operate on the appropriate pump
curve.
HEAT TRANSFER PILOT PLANT

(Learning Outcomes 3 )
HEAT
It is expected that students will be able to:
TRANSFER
Carry out an energy balance for the

tube side and the shell side
Compute the experimental overall

heat transfer coefficient for the heat
exchanger (for each run)
Plot on log-log scale the computed

experimental
heat
transfer
coefficient versus the shell side

Reynolds number.
Calculate the theoretical overall
heat transfer coefficient and
compare with the experimental
one.
*Please note that test dates may be moved on short notice where circumstances require
such change. Also, take particular note of the rules regarding tests and assignments in
section B, 2.6
6.2 LEARNING OUTCOMES AND ASSESSMENT CRITERIA

The following tables clearly indicate what you have to achieve (the learning outcomes) and
how you will be assessed (assessment criteria) to determine whether you have achieved the
required knowledge and competences:
LEARNING OUTCOME 1:
Load losses
Assessment criteria
Assessment method
Familiarize yourself with the pilot plant

and identify flow meter, manometer the
pump and its type and all different types of
pipes used on the pilot plant.
Oral test
Calculate the discharge coefficient, load

and frictional losses.
Written report
Correct raw data collection

Observation by lab personnel
Be able to correlate the results from the

experiment and the theoretical calculations.
Task performance
LEARNING OUTCOME 2:
Test bench pumps
Assessment criteria
Assessment method
Understanding of pumps, pump curves,

pump efficiency, pump relations i.e affinity
laws and energy balance concept.
Oral test
Task performance
Written report
LEARNING OUTCOME 3:
Heat exchanger
Assessment criteria
Assessment method
Knowledge and understanding of energy Oral test

balance equation
Ability to understand the types of flow and
the conditions they are applicable to.
Task performance
6.3
Written report
GENERIC OUTCOMES AND CRITICAL CROSS-FIELD OUTCOMES
Compliance with Critical cross-field Compliance with Generic Engineering and

Outcomes
Built Environment Outcomes
Knowledge and understanding of energy Problem solving
balance equation
Application of scientific and engineering
Communication and written skills
knowledge
Solving engineering problem
Communication skills
6.4 GLOSSARY OF TERMS

The following technical terms are used in this course, and you should be familiar with these
terms and their meanings.
Load losses; discharge co-efficient, friction factor, venture pipe and orifice pipe.
Test bench pumps; pump efficiency, torque, impeller, centrifugal pump relations, affinity laws
and NPSH.
Heat exchanger; heat transfer coefficient.
Sources used for the compilation of the glossary: Fluid flow for Chemical Engineers by H.
Randall
7. ASSESSMENT RECORDS
The following guideline for the preparation of report writing are attached to serve as examples
of the implementation of the assessment criteria and assessment method, as listed in the table
3.1, and you should be familiar with these examples to prepare and orientate yourself of how
the various assessment criteria are used and applied in the various assessment methods.
DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL
ENGINEERING
FLUIDFLOW PRACTICAL MANUAL
1. INTRODUCTION
The transport of fluid (liquid or gas) in closed conduits (commonly called pipe if it is of round
cross sectional area or duct if it is not round) is extremely important in our daily operations.
There is a variety of application of pipe flow with a range of very large constructed pipelines,
consider the pipelines carrying crude oil from oil rigs in the sea being pumped inland for
hundreds of kilometers, to a complex human beings blood and respiratory systems. (You can
think of many applications between the two extremes)
2. LAMINAR, TRANSITIONAL AND TURBULENT FLOWS
The flow of a fluid in a pipe may be laminar flow or it may be a turbulent flow. Osborne
Reynolds conducted a simple experiment of injecting a neutrally buoyant dye in a pipe of
diameter D carrying water with velocity V and observed the characteristics or behavior of the
fluid at very low flow rate, larger intermediate flow rate and large enough flow rate and later
denoted the three characteristics as laminar, transitional and turbulent flow, respectively. The
flow in a round pipe is laminar if Reynolds number is less than approximately 2100 and
turbulent if it is greater than 4000. For Reynolds numbers between the two limits, the flow is in
a transitional flow.
N RE
ud
3. GENERAL FORMULAE TO BE USED FOR THE HEAD LOSSES

EQUIPMENT.
NOTE: The drop in pressure, discharge coefficient and friction factor will calculated by using
the formulae:
i. P 10 5
fLu
2D
(bar)
where:
P = pressure drop (bar)

L = length of pipeline (m)
D = diameter of pipeline (m)
V= mean velocity of the fluid (m/s)
F = dimensionless friction factor
= density of the fluid (kg/m3)
4Q
ii. d 2 2 g P
where:
= discharge coefficient
Q = volumetric flow rate
g = gravity
2P
iii. K u 2 10 5
where:
K = friction factor
4. PIPE DIMENSIONS
COMPONENT
INNER DIAMETER (mm)
S.S Pipe DN 15
d = 18.10
S.S Pipe DN 20
d = 23.70
Cal. Orifice DN 25
d = 20.65
Venturi tube DN 25
d = 16.00
U bends
d = 30.50
L bends
d = 30.50
Enlargement
d = 18.10
OUTER DIAMETER(mm)
D = 30.50
Contraction
D = 30.50
d = 18.10
The distance between the measure points for all the tubes is 800mm.
5. PROCEDURE
Fill the tank with water.
Connect the pilot plant to the compressed air line.
Set the pressure of the pilot plant at 1.4 bar (plants operational pressure).
Connect the plant to the power supply.
Insert the E.L.C.B.
Start the pump by switching G1 from position 0 to position 1.
Increase or decrease the flow rate by pressing the from control panel.
The pressure can be read either from the mercury manometer or from the computer,
depending on whether the plant is operated manually or automatically via the computer.
Depending on the plant operation again, the pump output can either be read off from
the control panel or the computer.
6. STOPPING THE PLANT
Stop pump G1 by switching to position 0.
Switch off the main switch.
Disconnect the plant from the main power supply.
Close the feed of the compressed air.
Drain the tank by opening the drain valve.
7. EMERGENCY STOP
Press the red mushroom-head pushbutton.
8. PURPOSE
(a) Familiarize with methodology of determining the pressure drop experimentally.

(b) To determine the discharge coefficient, load and frictional losses on venture pipe and
orifice plate.
(c) To determine load and frictional losses on DN15 straight pipe, DN25 straight pipe, Ubend pipe, L-bend pipe, contraction pipe and enlargement pipe.
(d) To compare experimentally determined pressure drop with the calculated one from
equation.
Reference:
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Unit for the study of
load losses pilot plant
Compiled 2006 by: Molelekoa Mosesane

Revised 2007 by: Victor Hlongwane
PUMP TEST BENCH
AIM: CHARACTERIZATION OF THE PLANT.
INTRODUCTION.
The liquid transfer and circulation in piping is a problem of main importance for normal civil
applications (e.g. waterworks) as well as for the industry. It follows that it is important to know
the mechanisms of fluid transfer.
PUMP TEST BENCH BACKGROUND THEORY.
The pump test bench plant (or any plant operated with multiple pumps) can be characterized by
the regulation of the following manipulated variables:
The total head (H)
The power required to spin the shaft (Nshaft)
The power required to move the fluid (Nfluid)
The efficiency ()
These variables are taken indirectly from the following controlled variables:
The discharge pressure of the pump (Pdischarge)
The suction pressure (Psuction)
The flow rate (Q)
The revolution per minute of the pump (rpm)
The torque of the pump (C)
The formulae that gave us consent to detect, via the controlled variables, the manipulated
variables, have the following:
N fluid
(H Q )
in (kW)
102
(1)
Where:
H is the head calculated as (Pdischarge - Psuction)*10 and expressed in meters of water

column;
Q is the flow rate expressed in m3/s;
is the density of water, equal to 998 kg/m3 @ 22C;
102 is the conversion factor.
N shaft
(2n)
C 9.81 in (W)
60
(2)
Where:
n is the rpm;
C is the torque given by: arm weight * length, expressed in kg.m.
(%)
N fluid
Nshaft
100
(3)
The measurement will be made by changing the pump speed, i.e. the rpm and, different
flow rate will be set for each constant speed value. The following variables will be
detected for each of these conditions:
Variable measurement weight
Arm length, constant @ 0.05m

Suction pressure via manovacuometer, range: 1-3 bar
Discharge pressure via pressure gauge, range: 0-6 bar
Motor rotation speed of the pump G2, set via a digital revolution counter, range: 03000rpm
Pumps flow rate measured with two flow meters, measurement range: 600-6000l/h and
1000-10000l/h.
BY CHARACTERIZING THE CONTROLLED AND MANIPULATED VARIABLES,

THE FOLLOWING TASKS CAN BE EXECUTED.
Pump efficiency
Behavior of the efficiency (%) as a function of flow rate (Q in l/h) for fixed revolutions
per minute (e.g. 2800rpm).
Behaviour of the efficiency (%) as a function of flow rate (Q in l/h) for a range of
revolutions per minute (e.g. 29rpm 3000rpm).
Pressure developed (P in mH2O) as a function of flow rate (Q in l/h) for a range of
revolutions per minute (e.g 20rpm 3500rpm).
Pressure developed (P in mH2O) as a function of flow rate (Q in l/h) for fixed
revolutions per minute (2900rpm.
Pressure developed by pumps G1 and G2 in series versus pump G2 at constant speed of
2900rpm.
Pressure developed by pumps G1 and G2 in parallel versus pump G2 at constant speed
of 2900rpm.
CENTRIFUGAL PUMP RELATIONS.
The power PE required in an ideal centrifugal pump can be expected to be a function of the
liquid density , the impeller diameter D and the rotational speed of the impeller N. The
relationship is assumed to be given by the equation:
PE C1 N 3 D 5
(4)
Where C1 is a constant which depends on the geometry of the system. The power PE is also
proportional to the product of the volumetric flow rate Q and the total head h developed by
the pump given by:
PE C 2 Qh
(5)
Using pump G2, prove that the two equations are consistent. What conclusions can you
make from your experiment? Keep the speed of pump constant at 2800rpm.
The specific speed.

The specific speed is used as an index of pump type and is always evaluated at the best
efficiency point of the pump, given by:
N 's
N Q
(6)
( gh) 3 / 4
(N.B) All units must be consistent and in S.I units.
Determine the specific speed of pump G2.
Two pumps are said to be geometrically similar when the ratios of corresponding dimensions
in one pump are equal to those of the other pump. Geometrically similar pumps are said to be
homologous. A set of equations known as the affinity laws govern the performance of
homologous pumps at various speeds.
Affinity laws
Consider a centrifugal pump with an impeller diameter D1 operating at a rotational speed N1

and developing a total head h1. Consider an homologous pump with an impeller diameter D2
operating at a rotational speed N2 and developing a total head h2.
The following relations can be made:
Q1 N 1
Q2 N 2
and
D1
D2
(7)
h1 N 1
h2 N 2
D1
D2
(8)
Similarly:
PE1 N 1
PE 2 N 2
D1
D2
(9)
and by analogy with (8) the net positive suction heads for the two pumps can be related by the
equation;
NPSH 1 N 1
NPSH 2 N 2
D1
D2
(10)
A centrifugal pump with an impeller diameter 0.05m has the following performance data when
pumping water at the best efficiency point:
Impeller speed N
=2800rpm
Capacity Q
=10000l/hr
Total head h
=15.6m
Required net positive suction head NPSH
=2m
Brake power PB
=8000W
Evaluate the performance characteristics of a homologous pump with the impeller diameter
operating at half the impeller speed.
START UP AND RUNNING.
USE OF PUMPS INDIVIDUALLY.
PUMP G1.
Shut off valves V1, V6 and V9.

Open valves V2, V7 and V10.
Fill tank D1 with tap water.
Open valve V4 and fill the suction pipe of the pump with water.
Shut off valve V4.
Insert the E.L.C.B
Start pump G1 pushing the relative green pushbutton.
Adjust the flow rate Q using valve V10 and read the value on the flow meter FI1.
Detect the discharge pressure value on the pressure gauge PI2.
Detect the suction pressure value on the pressure gauge PI1.
PUMP G2.
Shut off valves V1, V6 and V9.

Open valves V3, V8 and V11.
Fill tank D1 with tap water.
Open valve V5 and fill the suction pipe of the pump with water.
Shut off valve V5.
Insert the E.L.C.B
Start pump G2 pushing the relative pushbutton.
Fix the rpm (e.g. 1500 rpm) using the potentiometer.
Adjust the flow rate using valve V11 or the potentiometer and read the value on the
flow meter FI2.
Detect the value of the torque C.
Detect the discharge pressure value on the pressure gauge PI4.
Detect the suction pressure value on the pressure gauge PI3.
PUMPS G1 AND G2 IN SERIES.
Shut off valves V1, V6, V7 and V11.

Open valves V2, V3, V6, V8 and V11.
Fill the tank D1 with tap water.
Open valve V4 and fill the suction pipe of pump G2 with water.
Shut off valve V5.
Insert the E.L.C.B
Start pump G2.
Fix the rpm (e.g. 1500rpm) using the potentiometer.
Adjust the flow rate Q via valve V11 reading the value fixed on the flow meter FI2.
Detect the discharge pressure gauge PI4.
Detect the suction pressure value via the vacuum meter PI3.
PUMPS G1 AND G2 IN PARALLEL.
Fill the tank D1 with tap water.

Shut off V1, V6 and V9.
Open valve V4 and fill the suction pipe of the pump G1 with water.
Shut off valve V4.
Open valve V5 and fill the suction pipe of the pump G2 with water.
Shut off valve V5.
Insert the E.L.C.B
Fix the rpm (e.g. 29rpm) using the potentiometer.
Open valve V9 and after close valve V10 to configure the pumps in parallel.
Adjust the flow rate via valve V11 and reading the value fixed on the flow meter FI2.
Detect the suction pressure value via the pressure gauge PI1 and PI3.
Detect the discharge pressure value in the pressure gauge PI2 and PI4.
STOP AND EMERGENCY STOP.
STOP
Stop pump G1 and G2 pushing the relative red pushbutton.
Switch off the E.L.C.B
For long stop period, drain tank D1 and disconnect the plant from the electrical
supply.
EMERGENCY STOP.
Push the emergency pushbutton.
Reference:
Holland F.A and Bragg R. Fluid flow for Chemical Engineers 1995, 152 154
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Test bench
pump pilot plant
Compiled by: Molelekoa Mosesane
DEPARTMENT OF CHEMICAL ENGINEERING
HEAT TRANSFER PILOT PLANT (SCVT) MANUAL
1. INTRODUCTION
Almost all operations of chemical engineering involve energy conversions, generating and
transferring heat. Therefore it is important to know how heat can be transferred between the
various systems.
In industry heat can be transferred from a fluid to another through various appliances: the most
important ones are heat exchangers; modern technology has developed several types of these
devices according to whether heat must be transferred between liquids, between liquids and
gases or vapour, or between gases.
2. HEAT TRANSFER
In thermodynamics, energy can be transferred between two bodies also as heat: this type of
transfer occurs thanks to a difference in temperature. The heat can be defined as the energy
which can be transferred due to difference in temperature between two bodies. This energy is
carried out through three distinct mechanisms, that is:
a. Heat conduction
b. Heat convection
c. Heat radiation
In the manual only heat of conduction and convection are treated because both these
phenomena need a material support, that is, they occur in the mass of a body.
3. HEAT CONDUCTION
Heat conduction is that type of heat transfer concerning heat exchangers without macroscopic
movement of matter. This phenomena absolutely occurs in solid bodies where there is no
relative movement of mass particles. The phenomena of heat conduction are regulated by
Fourier law.
Q
A(1 2 )
L
(1)
Where:
Q transferred
heat
L thickness of the body
1 temperature
2 = tempetature
A exchange surface
coefficient of thermal conductivity
m2
W/mC
4. HEAT CONVECTION
Heat convection is the type of heat transfer occurring particularly in liquids and gases. The
transport of thermal energy to the different points of the body occurs with a contemporary
movement of the mass particles forming the same body.
There are two types:
a. Natural convection: occurs when the movement of matter inside the mass of the
body is provoked by the transport of thermal energy.
b. Forced convection: occurring when the movement of matter inside the mass is
provoked by the external by the external factors (for example, by the difference of
pressure).
The phenomena of heat convection interesting this plant are those concerning the heat transfer
between a solid surface and a fluid skimming this surface. This manual will deal with forced
convection because only this type of heat transfer is developed in the heat exchangers of the
pilot plant SCTA.
The heat flow transferred between a surface and a fluid skimming it can be expressed by
Newtons law:
Q A( s f )
Where:
coefficient of heat convection.

A surface skimmed by the fluid.
s temperature of the skimmed surface.
f temperature of the fluid skimming the surface.
5. Tasks to be performed.
a. Spiral exchanger with counter-current flows.
Calculate dTmlg.
Do the heat balance.
Calculate the overall heat transfer coefficient.
b. Spiral exchanger with co-current flows.

Calculate dTmlg.
c. Shell and tube exchanger with counter-current flows

Calculate dTmlg.
Do the R and S calculations and determine Ft.
Calculation the overall heat transfer coefficient.
d. Shell and tube heat exchanger with co-current flows.

Calculate dTmlg.
Do the R and S calculations and determine Ft.
e. Plate heat exchanger with counter-current flows.
Calculate dTmlg.
6. START UP
(2)
Connect the plant to the mains: single phase + G; Pmax=1kW.
Connect the plant to the main water (valve FV2): max. consumption = 1000l/h, Pmax=2
bar.
Connect the plant to the mod. SCT01/EV or to a hot water line through the black rubber
hose (valve FV1): max. consumption = 1000l/h, Pmax= 2 bar.
Connect the plant to the compressed air line: max. consumption = 10Nm3/h; Set the
pressure reducer under the switch board at P=1.4 bar.
Insert the E.L.C.B.
Switch the selector AUT/PC in AUT position.
Close valves V14, V15, V16, V17 and V18.
Set the hot and cold water flow rates using the PID controllers:
a. Flow rate manual control.
Switch the loop of the controller n 1 (for the hot water) or n 2 (for the
cold water) in manual mode with the pushbutton.
Select the Out with the Ind pushbutton.
Set the Out (proportional to the opening of valve FV1 or FV2) for example
at 50% with the pushbutton .
Adjust the flow rate varying the Out with the pushbutton .
b. Flow rate automatic control.
Adjust the flow rate of hot and cold water in manual mode (see flow rate
manual control).
Select the set point with pushbutton SP-W.
Set the value of set point with pushbutton for example at 60%, equal to
600l/h).
Switch the loop in automatic mode with the pushbutton M/A/C (green led
on).
Adjust, if necessary, the value of gain and integral time of controller.
i.
Connect the spiral exchanger E3 with co-current flows.
Open the valve V1, V4, V5, V8 and V9.
Close valves V2, V3, V6, V7, V10, V11, V12, V13, V14, V15, V16, V17
and V18.
Set the hot water flow rate ( e.g 500l/h)
Set the cold water flow rate ( e.g 500l/h)
Wait a few minutes until the temperatures TI1, TI2, TI3 and TI4 are
stabilized; take note of the experimental data.
Vary the flow rate of the fluids up to the desired value, wait some minutes
and take note of the experimental data.
ii. Connecting the shell-and-tube exchanger E2 with co-current flows
Open the valves V2, V4, V5, V10 and V11.
Close the valves V1, V3, V6, V7, V8, V9, V12, V13, V14, V15, V16, V17
and V18.
Set the cold water flow rate (e.g 500l/h)
Wait some minutes until the temperatures TI5, TI6, TI7 and TI8 are
Vary the flow rate of the two fluids up to the desired value, wait some
minutes and take note of the experimental data.
iii.
Connecting the plate exchanger E3 with co-current flows.
and V18.
iii. Connecting the spiral the spiral exchanger E1 with counter-current flows.
and V18.
Set the hot water flow rate (e.g 500l/h).
Set the cold water flow rate (e.g 500l/h).
Wait some minutes until the temperatures TI1, TI2, TI3 and TI4 are stabilized;
take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some minutes
and take note of the experimental data.
iv. Connecting the shell-and-tube exchanger E2 with counter-current flows

and V18.
Connecting the plate exchanger E3 with counter-current flows.
and V18.
7.
8.
STOPPING THE PLANT
Close the pneumatic valve FV1.
Close the pneumatic valve FV2.
Close the main valve of hot water.
Close the main valve of cold water.
Connect the valves V14, V15, V16, V17 and V18 with a plastic hose to a
drain.
Drain the water of the exchangers opening the valves V14, V15, V16,
V17 and V18.
Disconnect the plant from the power supply.
Close the feed of the compressor.
EMERGENCY STOP.
Press the mushroom-head pushbutton.
Reference
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Heat transfer pilot
plant
COMPILED 2007 BY: MOLELEKOA MOSESANE
REVISED 2008 BY: MARCUS RANYAOA
FACULTY OF ENGINEERING AND BUILT

ENVIRONMENT
DEPATMENT OF CHEMICAL AND METALLURGICAL ENGINEERING
5. LABORATORY RULES AND RESPONSABILITIES

5.1 BASIC RULES
Always wear a laboratory coat.

Do not wear open shoes.
Do not eat or drink in the laboratory.
No horse-playing in the laboratory.
Always as the technician if you are not sure about anything.
5.2 RESPONSABILITIES
It is the students responsibility to make sure that she/he attends the practical sessions,
signs the attendance register, write practical report and submit on given due dates; as
this is crucial to succeed in this course.
Make sure that the engineering reports submitted are typed and binded.
6. OBJECTIVES
This practical experiment is to familiarize students with the operation of heat exchanger.
Students should be exposed to /or learn the following under the different operating conditions:
a) Heat transfer under parallel and counter flow.
b) Effect of different flow rates and temperature on rate of heat transfer.
c) Effect of different flow rates and temperatures on heat transfer coefficient.
54
6.1 THE FOLLOWING TASKS CAN BE PERFOMED

Determine:
a) The heat transfer rate of the heat exchanger.
b) The overall heat transfer coefficient.
c) The heat exchanger effectiveness at steady-state operation under the experimental
conditions(counter and parallel).
Reference:
Essom Company Limited, 510/1 Taksin RD., SOI 22/1. Bukkalo Thonburi, Bankok 10600,
Thailand, Tel, +66(0)24760034 FAX +66(0)24761500
Compiled by Mavuse SE, 03/2010

Rivised by Molelekoa Mosesane, 06/2010
FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL AND

METALLURGICAL ENGINEERING
CHEMICAL ENGINEERING LABORATORY
EXPERIMENT: _________________________________________________________________
Name: ________________________________________________________________________
Student Number: _______________________________________________________________
Group: _______________________________________________________________________
Date Experiment Performed: ______________________________________________________
Date Experiment Submitted: ______________________________________________________
Signature: ____________________________________________________________________
Submitted to: _________________________________________________________________
TSHWANEUNIVERSITY OF TECHNOLOGY
DEPARTMENT OF CHEMICAL AND METTALURGICAL ENGINEERING
REPORT GRADING FORM
Name of Student: ______________________________________________________________
Student Number: ______________________________________________________________
Title of Report: ________________________________________________________________
Term: ______________________________
DATE:______________________________
Subject
Max Mark
1.
Title Page
2.
Abstract
3.
Introduction
4.
Theoretical Background
5.
Procedure
6.
Results
7.
Discussion of Results
10
8.
Conclusion and Recommendations
9.
Literature Cited
10.
Nomenclature
11.
Organization and Neatness
A1
A2
Appendix
Raw Data
Data analysis and Sample
Calculations
TOTAL
Actual Mark
2
10
50
Lab technician/Lab assistant:_____________________________________________________

Signed: ______________________________________________________________________
Comments:

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FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT

DEPARTMENT OF CHEMICAL AND METELLURGICAL ENGINEERING

QUALIFICATION & SAQA ID

COMPILED BY (Molelekoa Mosesane)

COPYRIGHT : Tshwane University of Technology

Printed and distributed by :

ORGANISATIONAL COMPONENT CONTENTS:

3. ...............................................................Requirements, resources and recommended material.

Requirements for the course.......................................................................................10

LABORATORY, HEALTH & SAFETY RULES AND REGULATIONS.................16

Assessment methods and criteria...............................................................................17

6. ......................................................................................laboratory course content and schedule

schedule of laboratory sessions and assignments.......................................................20

Learning outcomes and assessment criteria................................................................21

Generic outcomes and critical cross-field outcomes..................................................22

Example of a practical report......................................................................................23

Guidelines for the Preparation of Written Reports...............................................................23

Heat exchanger pilot plant......................................................................................................39

ExampleS of mark sheets used during various assessments.......................................56

TEL NO AND EMAIL

(012) 382 3514

9012) 382 4655

3. REQUIREMENTS, RESOURCES AND RECOMMENDED MATERIAL.

REQUIREMENTS FOR THE COURSE

Laboratory Journal/Record Book Bookstore

Building 2 lab. 127

RECOMMENDED ELECTRONIC MATERIAL & WEBSITES

of the adjustments done before you attempt to operate it.

All power to the equipment and instruments should be turned off,

Regular attendance of the chemical engineering technology (IIIA) lectures is of primary

LABORATORY, HEALTH & SAFETY RULES AND REGULATIONS

Always wear a laboratory coat in the laboratory.

Do not wear open shoes in the laboratory.

Do not eat or drink in the laboratory.

No horse-playing in the laboratory.

Always ask the technician if you are not sure of anything.

ASSESSMENT METHODS AND CRITERIA

Data analysis and Sample

The practical mark will contribute 50% to the year mark

SCHEDULE OF LABORATORY SESSIONS AND ASSIGNMENTS

Obtain the relationship between the

f against log Re. Comment on your

Calculate system head

HEAT TRANSFER PILOT PLANT

It is expected that students will be able to:

Carry out an energy balance for the

Compute the experimental overall

Plot on log-log scale the computed

coefficient versus the shell side

6.2 LEARNING OUTCOMES AND ASSESSMENT CRITERIA

Familiarize yourself with the pilot plant

Calculate the discharge coefficient, load

Correct raw data collection

Be able to correlate the results from the

Understanding of pumps, pump curves,

Observation by lab personnel

Correct raw data collection

Knowledge and understanding of energy Oral test

GENERIC OUTCOMES AND CRITICAL CROSS-FIELD OUTCOMES

Compliance with Critical cross-field Compliance with Generic Engineering and

6.4 GLOSSARY OF TERMS

DEPARTMENT OF CHEMICAL ENGINEERING

FLUIDFLOW PRACTICAL MANUAL

2. LAMINAR, TRANSITIONAL AND TURBULENT FLOWS