WORK PROGRESS OF THE LEVEL 4 TERM I, UNDER GRADUATE THESIS

Aashique Alam Rezwan Sarzina Hossain

Topic Selection & Discussion Final Selected Topic:

Transient Heat Transfer Through Flame Resistance Fabrics

WEEK 1 & 2

WEEK 3
Submission of Work Plane and other Materials

Objectives: 1. To study the characteristics of heat transfer from a vertical hot jet of air impinging on two types of horizontally mounted plate, a flat and a convex plate and to compare the two results. 2. To study the performance of flame retardant fabrics in contact both with a flat and a convex plate. 3. To compare the heat transfer characteristics of flat and convex plate (with and without fabric). 4. Simulation of the heat transfer on flat and convex plate due to hot air impingement.
Expected Outcomes: 1. Characteristics of convective heat transfer due to air impingement on a convex plate. 2. Characteristics of heat transfer of a flame retardant fabrics used by the local fire fighter.

WEEK 4

Discussion on Previous Work

1. In the flat plate experiment for nozzle to plate separation z/d<3 the maximum Nussult number occurs slightly off the stagnation point. Within this distance the flow parallel to the surface is accelerated. At the end of the accelerated flow region the pressure gradient increases which leads to sudden rise in the turbulence level. The velocity increases slightly off the centre. The result is a sharp increase in the heat transfer co-efficient, h and hence higher Nu.
2. For z/d=1 there is secondary peak. Secondary peaks occur in the wall jet as a result of rising turbulence & falling velocity. 3. It can be concluded that for z/d<3 there is no specific relation between r/d and Nu because high turbulence. For z/d>3 the Nusselt number exponentially decays with the increasing r/d. 4. As the time increases heat flux decreases. 5. As the nozzle to plate separation distance increases heat flux also decreases.

WEEK 4 (CONTINUED)
6. For larger z/d separation the surface heat flux is fluctuating. This occurs due to the mixing of surrounding air with hot fluid creates an eddy current which in turns create fluctuation in reading. 7. When the experiment done with fabrics in contact with plate the maximum Nu occurred off the centre but no secondary peak occurred. So it can be said that the turbulence effect is less when fabrics is used.

8. Another non-contact testing is done where the fabric is 6mm away from the plate. This was done to compare the energy transfer within the gap. The different FR fabrics give different result but each of them proves to be more heat resistant when testing with air gap.
9. The results obtained using a shim stock testing is scattered with no definite pattern. They have concluded that the testing apparatus was not perfect to test such situation.

10. Adding 6mm air gap contributes to reducing the heat transfer between the plate and warm jet. As z/d become larger the Nu difference at centre became smaller. This is due to the appearance of maximum value at the stagnation point.

WEEK 5 STUDY OF SKIN TOLERANCE

Human Tissue Tolerance to Second Degree Burn Stoll, A.M. and Chianta, M.A. Method and Rating System for Evaluations of Thermal Protection Aerospace Medicine, Vol 40, 1969, pp. 1232-1238

WEEK 5 (CONTINUED)
Transient Heat Transfer Through Thin Fibrous Layers Performed by, Raul Munoz Anguiano Test Condition: Velocity of Air Jet: 13m/s

Temperature: 1024
Nozzle Diameter: 32mm Nozzle to Fabrics Distance: 128mm

SIMULATION OF THE TEST PERFORMED BY THE PREVIOUS AUTHOR

WEEK 5 (CONTINUED)

WEEK 5 (CONTINUED)
Heat and Mass Transfer in a Permeable Fabric System Under Hot Air Jet Impingement Proceedings of the International Heat Transfer Conference, August 8-13, 2010 ASME 2010

Test Condition:
Velocity of Air Jet: 32m/s Temperature: 100C and 200C Nozzle Diameter: 20.6mm Nozzle to Fabrics Distance: 76.2mm

ASTM STANDARDS FOR PROTECTIVE CLOTHING

F2703-08: Unsteady-State Heat Transfer Evaluation of Flame Resistant Materials for Clothing with Burn Injury Prediction Heat Flux: 84.6 kW/m2 Gas Pressure: 55 kPa Optional Spacer: 6.4mm

Minimum Sample Test: 5

Time of Exposure: 60s F2700-08: Standard Test Method for Unsteady-State Heat Transfer Evaluation of Flame Resistant Materials for Clothing with Continuous Heating

WEEK 6 EXPERIMENT ON WIND TUNNEL

Average Velocity Profile of the Wind Tunnel Exit
4 3.68 y = -2.31ln(x) + 6.9981

3 Radial Position

5.675

8.5

1 1

13.6 10 Velocity

100

WEEK 6 COMMENTS
Centerline Velocity at maximum opening of Wind Tunnel: 4.2 m/s

Maximum Velocity attained: 19.5 m/s

Average Velocity attained within the experimental range: 4.75 m/s

The exit velocity is not uniform due the presence of valve at the end. Velocity at the outside periphery is higher due to the turbulence created by the valve blade end. Thus only center portion of the tunnel cross-section is selected for the upcoming experiment.

PRIMARY DESIGN PARAMETERS

Nozzle Diameters = 25.4 mm (1 inch) Inlet Velocity = 4.75 m/s Expected Jet Velocity = 73.62 m/s

Inlet to Exit Pipe Length = 609.6 mm (24 inch)

Pipe diameter (internal) = 63.5 mm (2.5 inch)

Pipe Inlet Reducer = 101.6:63.5 mm (4:2.5 inch)

PRIMARY DESIGN NOZZLE

PRIMARY DESIGN (CONTINUED) NOZZLE PIPE ASSEMBLY

PRIMARY DESIGN (CONTINUED) NOZZLE PIPE ASSEMBLY

PRIMARY DESIGN (CONTINUED) NOZZLE PIPE ASSEMBLY

PRIMARY DESIGN (CONTINUED) NOZZLE PIPE ASSEMBLY

PREDICTED VELOCITY ALONG THE SETUP

PREDICTED VELOCITY ALONG THE SETUP

PREDICTED TEMPERATURE ALONG THE SETUP

PREDICTED TEMPERATURE ALONG THE SETUP

PREDICTED TEMPERATURE ON THE WALL

PREDICTED TEMPERATURE ON THE WALL

PRESSURE DISTRIBUTION

PRIMARY DESIGN COMMENTS

Primary Design Simulation shows a draw back in experimenting with surface heating for air heater, that it would require a tremendous amount of surface heat in short length, under which the material cant sustain. Further calculation was recommended for better design.

ASTM STANDARD
Thermal Sensor Copper Slug Calorimeter Diameter = 40.05cm Mass = 180.05g Electrical Grade Copper Thermocouple: ANSI Type J (Fe/Cu-Ni) or ANSI Type K(NiCr/Ni-Al) Wire Dia = 0.254 mm
ASTM Standard F 2703 - 08

Shutter

A manual or computer-controlled shutter is used to block the heat flux from the burner (placed between the specimen holder and the burner). Water cooling is recommended to minimize radiant heat transfer to other equipment components and to prevent thermal damage to the shutter itself.

Special Mid Term Session

MATHEMATICAL MODEL PRESENTATION

IMPINGING JET CHARACTERISTICS

Regions in submerged impinging round jet: Initial Free Jet

Core Region
Decaying Jet Region Stagnation Region Wall Jet Region

INITIAL FLOW REGION

Due to the application of differential pressure across thin flat orifice: Fairly flat velocity profiles

Less turbulence
A downstream flow contraction (vena-contracta)

INITIAL FLOW REGION

The shearing at the edges of the jet transfer momentum outward More fluid is entrained along with the jet Jet losses energy

The velocity profile is widened and decreased in magnitude

THE CORE REGION

Unaffected by the momentum transfer Higher total pressure

Experience a drop in velocity

Dynamic pressure decays as result of velocity gradient presence in the nozzle exit

DECAYING JET REGION

Juckerman and Lior defines the end of the core region as the axial position where the centerline flow dynamic pressure reaches 95% of its original value. Begins at 4~8D from the nozzle exit Axial velocity component decreased Axial velocity and jet width vary linearly

DECAYING JET REGION

Decaying jet region & free jet region may not exist if the nozzle lies within a distance of 2D from the target Elevated static pressure in the stagnation region influence the flow immediately at the nozzle exit

STAGNATION REGION
Flow losses axial velocity and turns

Builds up a higher static pressure on and above the wall

Experiences high normal and shear stresses in the deceleration region Stretches vortices in the flow and increases the turbulence Martin concluded that the region extends 1.2D above the wall for round jets

WALL JET REGION

Flow moves laterally outward parallel to the wall

Minimum thickness occurs within 0.75~3D from the jet axis, then continually thickens moving farther away from the nozzle
Boundary layers begins within the wall, where its thickness measures more than 1% of the jet Shearing layer influence by velocity gradient with respect to both at the wall and at the fluid outside the wall Entrains flow and grows in thickness

NOZZLE GEOMETRY TYPE ON JET IMPINGEMENT

MAJOR PARAMETERS
Nusselt Number, =

Convective Heat Transfer Coefficient =

Recovery factor =

2 2

Sherwood Number, = Heat to mass transfer rate,

= =

0.4

OTHER PARAMETERS
Prandlt Number, Pr
:

nozzle height to nozzle diameter ratio

r/D: nondimensional radial position from center of the jet z/D: nondimensional vertical position measured from the wall Turbulence intensity, Tu Renolds Number, Re Mach Number, M
:

jet center to center spacing (pitch)

Free Area,
Relative Nozzle Area,

EMPIRICAL CORRELATIONS
= ( ) For Single Round Nozzle, Martin correlation =
11.1 0.42 1+0.1( 6)

for 2,000<Re<30,000, F = 1.36 Re 0.574

for 30,000<Re<120,000, F = 0.54 Re 0.667 for 120,000<Re<400,000, F = 0.151 Re 0.775

EMPIRICAL CORRELATIONS

FLAME IMPINGEMENT
Transfer heat very effectively and tends to have higher turbulence

If some fuel travels through the stagnation region without complete combustion, further reaction in the wall jet will release additional thermal energy and improve uniformity Also transfer heat by radiation from the flame
60-70% heat transfer by convection [Malikov et al] Accumulation of soot may occur on the target which ultimately impede heat transfer

TRANSIENT HEAT TRANSFER

Governing equation,
2 2

Boundary condition, T(x,0) = Ti , T(0,t) = Ts Solving,

, 0 0

= erf

For constant heat flux =

2

2 4

TRANSIENT HEAT TRANSFER

GOVERNING EQUATIONS FOR THE FABRICS

For gas phase in the Fabric Layer

Mass Conservation Equation

= 0

Momentum Conservation Equation

1 2 + 1/2 2

GOVERNING EQUATIONS FOR THE FABRICS

Energy Conservation Equation

Energy Conservation Equation for Fabric Phase

1

GOVERNING EQUATIONS FOR THE AIR GAP

Mass Conservation Equation

= , ,

Where,

, = |=
, =

GOVERNING EQUATIONS FOR THE AIR GAP

Energy Conservation Equation

= , , + ,
, ,

, =

, =

, = 1 =

|=

THERMOPHYSICAL PROPERTIES OF FABRICS

THERMOPHYSICAL PROPERTIES OF FABRICS

WEEK 7 TYPICAL HEATING & FLOW ARRANGEMENT

WALL TEMPERATURE REQUIRED FOR THE DESIRED OUTLET TEMPERATURE

Wall Temperature Required with the Heating Zone Length
1000

900
800 700 Temperature (C) 600 500 400 300 200 100 0 0 0.5 1 1.5 Length (m) 2 2.5 3 3.5

Week 7

NICHROME WIRE PARAMETERS

Gauge Wire 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Ohms/ft at Room Temperature Diameter (mm) NiCr A 2.591 0.06248 2.311 0.07849 2.057 0.09907 1.829 0.12540 1.626 0.15870 1.448 0.20010 1.295 0.24990 1.143 0.32100 1.016 0.40630 0.914 0.50150 0.813 0.63480 0.7239 0.80020 0.6426 1.01500 0.5740 1.27300 0.5105 1.60900 0.4547 2.02900 0.4039 2.571 0.3607 3.224 0.3200 4.094 0.2870 5.090 0.2540 6.500 0.2261 8.206 0.2032 10.160 0.1803 12.890 0.1600 16.380 0.1422 20.730 0.1270 26.000 0.1143 32.100 0.1016 40.630 0.0889 53.060

NiCr C 0.06488 0.08151 0.10290 0.13020 0.16480 0.20780 0.25950 0.33330 0.42190 0.52080 0.65920 0.83100 1.05500 1.32200 1.67100 2.10700 2.670 3.348 4.252 5.286 6.750 8.522 10.550 13.390 17.010 21.520 27.000 33.330 42.190 55.100

Approximate Amperes to Heat NiChrome Wire

Gauge Wire 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Diameter (mm) 2.591 2.311 2.057 1.829 1.626 1.448 1.295 1.143 1.016 0.914 0.813 0.7239 0.6426 0.5740 0.5105 0.4547 0.4039 0.3607 0.3200 0.2870 0.2540 0.2261 0.2032 0.1803 0.1600

400F 205C 16.2 13.8 11.6 9.80 8.40 7.20 6.40 5.50 4.80 4.30 3.80 3.30 2.90 2.58 2.21 1.92 1.67 1.44 1.24 1.08 0.92 0.77 0.68 0.59 0.50

600 316 23.3 19.2 16.1 13.6 11.6 10.0 8.70 7.50 6.50 5.80 5.10 4.30 3.70 3.30 2.90 2.52 2.14 1.84 1.61 1.41 1.19 1.03 0.90 0.79 0.68

800 427 29.7 24.8 20.8 17.6 15.0 12.8 10.9 9.50 8.20 7.20 6.30 5.30 4.50 4.00 3.40 3.00 2.60 2.25 1.95 1.73 1.47 1.28 1.13 0.97 0.83

1000 538 37.5 31.5 26.5 22.5 18.8 16.1 13.7 11.7 10.1 8.70 7.60 6.50 5.60 4.90 4.20 3.60 3.20 2.73 2.38 2.10 1.78 1.54 1.36 1.17 1.00

1200 649 46.0 39.0 33.5 28.2 23.5 20.0 17.0 14.5 12.2 10.6 9.10 7.80 6.80 5.90 5.10 4.30 3.80 3.30 2.85 2.51 2.14 1.84 1.62 1.40 1.20

1400 760 56.0 48.0 40.8 34.2 29.0 24.5 20.9 17.6 14.8 12.7 11.0 9.40 8.20 7.00 6.00 5.20 4.50 3.90 3.40 2.95 2.52 2.17 1.89 1.62 1.41

1600 871 68.0 57.0 48.0 41.0 34.6 29.4 25.1 21.1 17.7 15.2 13.0 11.0 9.60 8.30 7.10 6.10 5.30 4.60 3.90 3.40 2.90 2.52 2.18 1.86 1.60

1800 982 80.0 67.0 56.0 48.0 40.5 34.3 29.4 24.6 20.7 17.8 15.2 12.9 11.0 9.60 8.20 7.10 6.10 5.30 4.50 3.90 3.30 2.85 2.46 2.12 1.80

2000 1093 92.0 78.0 65.0 55.0 46.0 39.2 33.6 28.1 23.7 20.5 17.5 14.8 12.5 11.0 9.40 8.00 6.90 6.00 5.10 4.40 3.70 3.2 2.76 2.35 1.99

Characteristics Chart of NiCr A Volt 220V

220.00 210.00 200.00 190.00 180.00 170.00 160.00 150.00 140.00 130.00 205C 316C 427C 538C

120.00
Length (ft) 110.00 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Gauge 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Characteristics Chart of NiCr C Volt 220V

220.00 210.00 200.00 190.00 180.00 170.00 160.00 150.00 140.00 130.00 427C 205C 316C

538C

120.00
Length (ft) 110.00 100.00 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Gauge 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Gauge Size - Resistance Of NiCr C

1000.0000 950.0000 900.0000 850.0000 800.0000 750.0000 700.0000

650.0000
600.0000 Resistance (ohms) 550.0000 500.0000 450.0000 400.0000 350.0000 300.0000 250.0000 200.0000 150.0000 100.0000 50.0000 0.0000 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Gauge Size 205C 316C 427C 538C

REQUIRED LENGTH FOR THE AVAILABLE WALL TEMPERATURE

Required Length for the Wall Temperature to Raise the Flowing Fluid Temperature to 105C
3.5 3 2.5 2 1.5 1 0.5 0 0 100 200 300 400 500 Temperature (C) 600 700 800 900 1000

Length (m(

RECOMMENDATIONS (WEEK 7)
The design with only wall heating is complicated in a sense of physical setup constrain For heating purpose, more reliable and higher heat transfer system may be design

Internal Fin type heat exchanger may be design with NiChrome Wire heater
From the NiChrome Wire Properties, 30 gauge wire with 316C heating can be recommended for design Further study required for designing other type of heat exchanger

WEEK 8 BUDGET ESTIMATION

Item Description 2 GI Pipe For heating space & flow control 1 GI Pipe For jet impingement both in Air and Steam 4 x 2 Socket To reduce the flow 2 x 1 Socket To make the jet 1 90 Bends To control the steam Flange with 4 hole For setting up with the wind tunnel Unit Price 240/- per feet No. of Unit Required 5 ft Total Price 1200/Piping for Jet Impingement for both Air & Steam

80/- per feet

5 ft

400/-

600/300/60/85/- per kg

1 1 5

600/300/300/-

Specimen Holder Plastic Pipe To flow shield cooling water Steel Sheet 28 gauge For thermal shield 15/- per feet

140/- per running feet

2 x 2 sq. feet

560/-

Wood Structure
Thermocouple Measuring Plate

BUDGET ESTIMATION (CONTINUED)

Heating Coil
Type
Rod Shape

Size
8 ~ 18
12 12 8 8 12

Wattage Rating
400W ~ 3000W
2000W 1200W 400W 600W 500W

Unit Price
200/- ~ 1200/450/350/250/400/350/4 feet 400/-

Ring Shape (Finned) U Shape Locally assembled Coil

CALCULATION WITH INTERNAL FIN HEATER

CONFIGURATION 1: TUBE BANKS PARALLEL TO THE FLOW DIRECTION

CALCULATION (CONTINUED)
Initial Condition:

205C

Inlet Air Temperature = 30C

Heater Wall Temperature =

Correlation: Nu=0.37 Re^0.8 for 17 < Re < 70000 McAdams, W. H., Heat Transmission, 3rd ed., New York, McGraw-Hill, 1954

CALCULATION (CONTINUED)

CONFIGURATION 2: TUBE BANKS ACROSS THE FLOW

CALCULATION (CONTINUED)
Initial Condition:

Inlet Air Temperature = 30C

Heater Wall Temperature = 205C Correlations: Knudsen and Katz suggested, Nu=C Re^n Pr^(13)

For Tube Banks of 4 rows high and 6 rows deep,

C = 0.27 n = 0.63 From Table 6-6 and Table 6-7

[Zukauskas, A., Heat Transfer from Tubes in Cross Flow, Adv. Heat Transfer, vol 8, pp 93-160, 1972]
Temperature Increased per Stage: 20.2C

WEEK 8 COMMENTS
The calculation shows better heating can be achieved with this type of arrangement. Further calculation on the same arrangement but different configuration was recommended. Final design was encouraged to submit within the next week.

Simulating using CFD module was planned for the final design.

WEEK 9
Provisional Advanced Bill was submitted for sanction Extended Abstract was submitted for participating in the ICME 2011

WEEK 10
SIMULATION OF THE TESTING EQUIPMENT DESIGNED WITH ADIABATIC WALL CONDITION

DESIGN CHECK 2

DESIGN CHECK 2 (CONTINUED)

DESIGN CHECK 3

DESIGN CHECK 3 (CONTINUED)

WEEK 10 COMMENTS
The simulation showed a major drawback in the design that - the surface temperature increased tremendously at the end of the tube - the temperature attained using fixed heat transfer is not perfectly correct due to the physical constrain and the nature of heat transfer in the air Further modification was recommended by using baffle or extended chamber

WEEK 11 REDESIGN

REDESIGN (CONTINUED)

REDESIGN (CONTINUED)

REDESIGN COMMENTS
Temperature of the air attained is about 110C - which is required for the testing of fabric But the surface temperature of the Fin/Tube Heater is maximum about 2437C at some places - which will cause the heater to melt or break away before it reaches that high temperature Modification is recommended for the design

FINAL DESIGN

AIR JET IMPINGEMENT SETUP

SECTIONAL VIEW OF SETUP

SPECIMEN HOLDER

FINAL DESIGN SIMULATION

FINAL DESIGN (CONTINUED)

FINAL DESIGN (CONTINUED)

FINAL DESIGN (CONTINUED)

FINAL DESIGN (CONTINUED)

FINAL DESIGN (CONTINUED)

FINAL DESIGN (CONTINUED)

COMMENTS
Air Temperature Expected: 120C Maximum Surface Temperature of Heater: 630C Jet Velocity Expected: 74 m/s

CONSTRUCTION OF THE SETUP

CONSTRUCTION 2 INCH PIPE & REDUCER

CONSTRUCTION (CONTINUED) 4 INCH PIPE WITH FLANGE

CONSTRUCTION (CONTINUED) 2 INCH PIPE & 1 INCH REDUCER

CONSTRUCTION (CONTINUED) FLANGE

CONSTRUCTION (CONTINUED) WOODEN FABRIC HOLDER

CONSTRUCTION (CONTINUED)

PLAN FOR NEXT TERM

1. Testing of the setup:

(a) After establishing the structure, the data acquisition system will be assembled with it.
(b) Then the calibration of testing equipment will be done. 2. Experiment on flame resistant fabric: Testing upon fabric will be performed by hot air jet impingement. 3. Calculation on the experimental value

Calculation on the experimental value and later comparison on the result will be done .

PLAN FOR NEXT TERM (CONTINUED)

4. Comparing experimental result with Computer simulation

Computer simulation will be made using ANSYS CFX and ANSYS FLUENT. The experimental result will be compared with the simulation. The mathematical model will be verified by using the appropriate technique 5. Analysis on skin burning effect The result will be analyzed with the skin burning effect on heat flux and will be determined whether the fabric can reduce the flame heating on skin

PLAN FOR NEXT TERM (CONTINUED)

6. Study on steam impingement and steam exposures

Further study will be done on steam and a comparative study will be presented on steam impingement technique.
The previous research on flame impingement shows that the significant difference between the air impingement and steam impingement. The momentum effect of steam is more acute than air. Further, the condensation occurs in the stagnation point will cause more heat flux upon the fabric material. Some recommendations will be presented on steam modeling and experimental constrained. The effect of steam exposures can also be studied because in many cases, the steam exposure may causes accident during working and emergency situation.

PREPARED BY AASHIQUE ALAM REZWAN (06 10 012) IN ASSOCIATION WITH SARZINA HOSSAIN (06 10 063)
SPECIAL THANKS FOR CONSTRUCTION WORK OF THE SETUP

A K M NAZRUL ISLAM (MASTERS STD)

Under Supervision of Dr. Ashraful Islam Professor, Department of Mechanical Engineering Bangladesh University of Engineering & Technology