Long Exam #2: Fluid Machineries and Heat Transfer

Industrial Plant Engineering

June 30, 2025

Name:

Section:

Question Points
1 50
2 50
3 50
4 50
5 50
6 50
7 50
8 50
9 50
10 50
Total 500

Instructions:

1. This examination contains 11 pages, including this page.

2. You have 4 hours to complete the long examination.

3. Provide a full-blown solution, illustrate the PV and TS, and schematic diagrams if necessary.
4. Please box your final answers per given questions needed. Avoid rounding off immediately if it is still
not the final answer.
5. Please sign the below Honor Code statement.

Any form of cheating will be subjected to disqualification on the final examination. I shall honor integrity
and accountability.

Signature:

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Problem 1

A steam generator supplies 180,000 kg of steam per hour at 5.5 MPa absolute and 540°C with feedwater at
176°C. At this output, the thermal efficiency is 85% when burning 42,456 kJ/kg fuel oil at 15% excess air.
The products of combustion with an average molecular weight of 30 are removed from the unit by a pair of
duplicate induced-draft fans operating in parallel, and the flue gas temperature at each fan suction is 150°C.
Estimate the power capacity of each fan using the following rule:

7.5 kg air is required for perfect combustion of each 23,200 kJ/kg heat value of oil.

The fan differential pressure is 190 mm water column (WC). Take note that At P = 5.5 MPa, t = 540◦ C,
the enthalpy of steam is hs = 3520 kJ/kg. At t = 176◦ C, the enthalpy of feedwater is hf = 746 kJ/kg.

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Problem 2

Water steadily flows through the pump system as shown in the figure. These data apply:

D1 = 1 ft, D2 = D3 = 0.5 ft; p1 = 12 psig, v1 = 10 fps; propeller input energy, Wp = 3.91 hp.

Assume that the internal energy and the density remain constant. Calculate for the following:

Figure 1: Problem 2

(a) velocity at point 2 in fpm

(b) gage pressure at point 2 in kgf/cm2

(c) gage pressure at point 3 in inHg

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Problem 3

Air is compressed in a two-stage, double-acting compressor from an initial pressure of P1 = 14.3 psia and
temperature of T1 = 90◦ F, to a final pressure of P3 = 185 psia. The mass flow rate of air is ṁ = 90 lb/min.
The barometric pressure and ambient temperature are Patm = 14.63 psia and Tatm = 80◦ F, respectively.
The pressure drop in the intercooler is ∆Pintercooler = 3 psi, and the temperature of the air at the intercooler
exit is T2 = 90◦ F. The polytropic relation pV 1.34 = constant holds for both compression and re-expansion
processes. The clearance volume is c = 5%, and the rotational speed of the compressor is N = 210 rpm. The
cooling water temperature increases by ∆Tw = 18◦ F as it absorbs heat from the compressed air.
Determine the following:

(a) The cubic feet per minute (cfm) of free air handled.
(b) The discharge pressure of the low-pressure (LP) cylinder for minimum work.
(c) The temperature at discharge from both LP and high-pressure (HP) cylinders.

(d) The mass rate of cooling water to be circulated around each cylinder and through the intercooler.
(e) The conventional horsepower.
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(f) If, for the LP cylinder, the length-to-diameter ratio is D = 0.68, and if both cylinders have the same
stroke, what should be the cylinder dimensions? Neglect piston rod effects.

(g) Let the actual volumetric efficiency be 88% and the size of the compressor be as found in part (f).
Find the actual mass of air delivered per minute.
(h) If the adiabatic compression efficiency is 78%, and if the mechanical efficiency of the compressor is
85%, what should be the horsepower output of the driving motor?

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Problem 4

The internal diameter of a boiler generating tube is 4 in. and the wall thickness is 0.375 in. In operation,
the external surface film coefficient is houtside = 26 Btu/hr · ft2 · ◦ F, the internal film coefficient is hinside =
1700 Btu/hr·ft2 · ◦ F, and a 0.375 in. thickness scale having a thermal conductivity of kscale = 0.6 Btu/hr·ft· ◦ F
is deposited on the inner surface of the tube.The metal thermal conductivity is kmetal = 26 Btu/hr · ft · ◦ F,
the furnace gas temperature is Tgas = 2100◦ F, and the water temperature is Twater = 500◦ F.

Figure 2: Problem 4

Calculate for the following:

(A) The overall heat transfer coefficient for the clean tube (no scale), in Btu/hr·ft2 · ◦ F
(B) The overall heat transfer coefficient including the effect of the scale, in Btu/hr·ft2 · ◦ F
(C) The external tube surface temperature before and after the scale has formed
(d) The amount of heat transferred per unit length

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Problem 5

Consider a large plane wall of thickness L = 0.05 m. The wall surface at x = 0 is insulated, while the surface
at x = L is maintained at a temperature of 30◦ C. The thermal conductivity of the wall is k = 30 W/m · ◦ C,
and heat is generated in the wall at a rate of
3 3
ġ = g0 e−0.5x/L W/m , where g0 = 8 × 106 W/m .

Assuming steady one-dimensional heat transfer:

(a) Determine the temperature of the insulated surface of the wall.

(b) During ambient conditions, the surrounding convection coefficient is at 31 W/m2 − K and the a tem-
perature of 35◦ C. With the radiation effects, emissivity was 0.95 and the sky temperature is 100◦ C.
Using the conditions aforementioned, what would be the new outer temperature of the plane wall?

(c) Using the conditions at b, what would be the new temperature centerline rise and the maximum
temperature at the insulated surface of the wall?

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Problem 6

Consider a long resistance wire of radius r1 = 0.2 cm and thermal conductivity kwire = 15 W/m· ◦ C, in which
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heat is generated uniformly as a result of resistance heating at a constant rate of ġ = 50 W/cm . The wire
is embedded in a 0.5 cm-thick layer of ceramic whose thermal conductivity is kceramic = 1.2 W/m · ◦ C. If the
outer surface temperature of the ceramic layer is measured to be Ts = 45◦ C, determine the temperatures at
under steady-state conditions.:

Figure 3: Problem 6

(a) the center of the resistance wire, and

(b) the interface of the wire and the ceramic layer

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Problem 7

A 10-in.-thick, 30-ft-long, and 10-ft-high wall is to be constructed using 9-in.-long solid bricks (k = 0.40 Btu/h·
ft · ◦ F) of cross section 7 in. bricks with nine square air holes (k = 0.015 Btu/h · ft · ◦ F) that are 9 in. long
and have a cross section of 1.5 in. × 1.5 in. There is a 0.5-in.-thick plaster layer (k = 0.10 Btu/h · ft · ◦ F)
between two adjacent bricks on all four sides and on both sides of the wall. The house is maintained at 80°F
and the ambient temperature outside is 30°F. Taking the heat transfer coefficients at the inner and outer
surfaces of the wall to be 1.5 and 4 Btu/h·ft2 · ◦ F, respectively, compute for the following:

Figure 4: Problem 7

(a) rate of heat transfer through the wall constructed of solid bricks

(b) rate of heat transfer through the wall constructed of bricks with air holes.

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Problem 8

A 4-pass low-pressure surface-type feedwater heater is designed to heat 92,730 kg/hr of feedwater from an
initial temperature of 40◦ C to a final temperature of 80◦ C using steam bleed at 70 kPa (absolute) containing
2,645 kJ/kg of enthalpy. Assume no subcooling of condensate. The specifications of the Muntz metal tubes
to be installed has an outer diameter of 19 mm and a wall thickness of 2 mm; the water velocity inside
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the tubes is 1.22 m/s and the overall heat transfer coefficient is U = 3000 W/m -K, based on the external
surface of the tubes. Note that the wet steam entering becomes condensate at 70 KPa has an enthalpy of
376.7 KJ/kg and 90°C.
Determine the following:

(a) The total length of tube required per tube (in ft).
(b) The total tube length required (in ft).
(c) The total number of tubes to be used in each pass.

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Problem 9

Hot water at an average temperature of 80°C and an average velocity of 1.5 m/s is flowing through a 25-m
section of a pipe that has an outer diameter of 5 cm. The pipe extends 2 m in the ambient air above the
ground, dips into the ground (with k = 1.5 W/m · °C) vertically for 3 m, and continues horizontally at this
depth for 20 m more before it enters the next building. The first section of the pipe is exposed to the ambient
air at 8°C, with a heat transfer coefficient of 22 W/m² · °C. If the surface of the ground is covered with snow
at 0°C, determine:

Figure 5: Problem 9

(a) the total rate of heat loss from the hot water,
(b) the temperature drop of the hot water as it flows through this 25-m-long section of the pipe.

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Problem 10
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Engine valves (k = 48 W/m · ◦ C, Cp = 440 J/kg · ◦ C, and ρ = 7840 kg/m ) are heated to 800◦ C in the heat
treatment section of a valve manufacturing facility. The valves are then quenched in a large oil bath at an
2
average temperature of 45◦ C. The heat transfer coefficient in the oil bath is 650 W/m · ◦ C. The valves have
a cylindrical stem with a diameter of 8 mm and a length of 10 cm. The valve head and the stem may be
assumed to be of equal surface area, and the volume of the valve head can be taken to be 80 percent of the
volume of the stem.

(a) Determine how long it will take for the valve temperature to drop to 400◦ C
(b) Determine how long it will take for the valve temperature to drop to 200◦ C at relative equilibrium

(c) The characteristic length of the valve design

(d) The maximum heat transfer from a single valve

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