Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779

www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-014-1044-z

Heat transfer enhancement by helical screw tape coupled with rib turbulators
Kwanchai Nanan1, Monsak Pimsarn2, Chinaruk Thianpong2 and Smith Eiamsa-ard1,*
1
Faculty of Engineering, Mahanakorn University of Technology, Bangkok 10530, Thailand
2
Faculty of Engineering, King Mongkuts Institute of Technology Ladkrabang, Bangkok 10520, Thailand

(Manuscript Received February 12, 2014; Revised June 5, 2014; Accepted June 28, 2014)

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Abstract

The influence of helical screw tape coupled with rib turbulators (HST-R) on thermohydraulic characteristics in a circular tube has been
experimentally investigated. The experiments were performed under constant heat flux condition for Reynolds number between 6,000
and 20,000. The rib-pitch ratio (p/D) was varied from 1.0 to 3.0 while rib-height ratio (e/W) was varied from 0.5 to 1.5. The experimental
results revealed that heat transfer and friction factor increase with increasing rib-height ratio (e/W) and decreasing rib-pitch ratio (p/D).
For the range examined, the HST-Rs with moderate rib-pitch ratio (p/D = 2) and the largest rib-height ratio (e/W = 1.5) gave the maxi-
mum thermal performance factor while HST possessed thermal performance factor around average value of those of the tubes with HST-
Rs. The developed empirical correlations for Nusselt number, friction factor and thermal performance factor gave the predictions within
4.4%, 13% and 4.2%, respectively as compared to the experimental data.
Keywords: Heat transfer exchanger; Rib turbulator; Helical tape; Swirl flow; Turbulence
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caused significant lower friction factor with only moderate

1. Introduction
decrease of Nusselt number as compared to those given by the
Improving heat exchanger performance brings beneficial ef- conventional HSTs for both low and high Reynolds number
fects for industrial and engineering applications including regions. Numerical results by Zhang et al. [15] reveled that
compactness, economy in manufacturing and operating costs HST with four different widths (w = 7.5 mm, 12 mm, 15 mm
as well as energy conservation. This strongly motivates re- and 20 mm) gave overall heat transfer coefficients around
search in heat transfer enhancement [1]. Turbulence flow gen- 212% to 351% higher than that in plain tubes, accompanied
erator is one of the techniques for increasing the composite by 33% to 1020% friction factor increase. The thermal per-
velocity, making eruption of the thermal boundary layer, en- formance value of the HST inserts of different width varied
hancing the tangential and radial turbulent fluctuation, and between 1.58 and 2.35. Sivashanmugam and Nagarajan [16]
therefore causes the increase in the heat transfer inside a heat and Jaisankar et al. [18] proved that the heat transfer coeffi-
exchanger tube [2-10]. Helical screw tapes (HSTs) have been cients and thermal performance factors given by right-left
used to introduce a swirl or turbulent near the tube wall which HST inserts were higher than those given by conventional
results in more efficient fluid mixing between near wall and HST. The triple HSTs invented by Bhuiya et al. [20] gave
core regions. The tapes were extensively modified for heat thermal performance based on constant blower power as high
transfer enhancement such as regularly-spaced helical tape as 3.7. Eiamsa-ard et al. [21] reported that the helically twisted
[11-13], helical screw-tape with/without core-rod [14, 15], tapes inducing co- swirl flows (co-HTT) gave lower heat
right-left helical screw tape [16-18], double helical tapes [19], transfer coefficient and friction factor but higher thermal per-
triple helical screw tapes [20], co/counter helical screw tape formance factor than the helically twisted tapes inducing
[21] and double/triple helical twisted tapes [22]. counter-swirl flows (C-HTT). Recently, Eiamsa-ard et al. [22]
Open literatures showed that modified HSTs gave a broad reported that although double helical twisted-tapes (D-HTTs)
range of heat transfer results depending on their geometries and triple helical twisted-tapes (T-HTTs) gave higher Nusselt
and operating conditions. Sivashanmugam and Suresh [12] number than the single helical twisted-tape (S-HTT), they
reported that regularly-spaced HSTs offered better results for caused significantly higher friction factor. This led to poorer
heat transfer enhancement than conventional HSTs since they overall result notified by the lower thermal performance factor.
*
Corresponding author. Tel.: +662 9883666, Fax.: +662 9883666
In addition, as width ratio increased, both heat transfer coeffi-
E-mail address: smith@mut.ac.th cient and pressure drop were considerably increased. However,

Recommended by Associate Editor Dae Hee Lee due to the poorer trade-off between the increases of heat trans-
KSME & Springer 2014
4772 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779

(a) Conventional HST (b) Rib turbulators

(c) HST-Rs with p/D = 1.0

(d) HST-Rs with p/D = 2.0

(e) HST-Rs with p/D = 3.0

Fig. 1. Helical screw tape with rib turbulators.

fer coefficient and pressure drop, lower thermal performance

factor was consistently obtained at the conditions possessing
higher heat transfer coefficient.
Although HSTs have been extensively modified, coupling
rib turbulators with conventional HSTs has not been reported,
so far. In common, ribs are adopted to form artificial rough-
ness, which provide heat transfer enhancement by generating
vortices [23]. Therefore, the coupling ribs with HST is likely
to give combined effect of common swirl and vortex in the
flow which should give rise to stronger turbulent intensity and
thus better fluid mixing as compared to those given by HST or
ribs alone. This motivates the study on heat transfer enhance-
ment associated by the helical screw tape coupled with rib
tabulators (HST-R). In the present study, ribs were mounted
on helical tapes at different rib-pitch ratios (p/D) of = 1.0, 2.0,
and 3.0 and rib-height ratio (e/W) was varied between 0.5 and
1.5. Air was used as the testing fluid under uniform wall heat
flux condition.
2. Model of HST-R
The geometrical configuration of helical screw tape coupled
with rib tabulators (HST-R) is shown in Fig. 1. HSTs were
made of aluminum sheets with length (L), thickness (t) and
width (W) of 1,500, 1.2 and 12.6 mm, respectively. Ribs were
made of aluminum strips with width of 12.6 mm and thickness
of 1.0 mm. The HST-R was fabricated by winding uniformly
a strip of 12.6 mm width over a 39 mm rod, then welding
aluminum ribs on the tape. The helical twist ratio (y/D) of a
HST defined as the ratio of length of one twist to diameter of a
tube was fixed at 2.0. Ribs were mounted on tapes at three
different rib-pitch ratios (p/D) of = 1.0, 2.0, and 3.0, and three
different rib-height ratios (e/W) of 0.5, 1.0 and 1.5, (corre-
sponding to rib heights of 6.3, 12.6 and 18.9 mm, respec-
tively). Finally, each HST-R was inserted into the copper test
tube with 1,500 mm in length, 63 mm in diameter and 1.75
mm in thickness.
 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779
Fig. 2. Experimental heat transfer set-up.
3. Experimental facility
The experimental facility in the present investigation (Fig.
2) consisted of a test tube (calm and test sections), 3 hp high
pressure blower, a set of T-type thermocouples, pressure taps,
data acquisition system, personal computer, hot wire ane-
mometer, inverter, U-tube or inclined manometer, power sup-
ply system and other support structures [22]. In the experiment,
the pressure taps were located around 1260 mm (20D) up-
stream and 630 mm (10D) downstream of the test section. The
distance between both taps was around 3390 mm. A hot wire
anemometer was installed in front of the orifice meter to cali-
brate the orifice meter for flow measurement. The test section
was uniformly wound with a Nichrome wire in porcelain
beads to minimize convective heat loss to surroundings, and
necessary precautions were also taken to minimize heat loss.
During experiments, inlet bulk air at 27C was drawn through
the calm section to achieve a fully developed flow prior to
being heated by an adjustable electrical heater wrapping along
the test section. Air flow rate was varied from 0.0059 kg s-1 to
0.0187 kg s-1 corresponding to Reynolds number (Re) from
6,000 to 20,000. In each run, HST-R was inserted into the test
section (one set for each run). In addition, a conventional heli-
cal screw tape (HST) was also tested for comparison. The
electrical output power was controlled via variac transformer
by keeping the current below 3 amps to achieve a constant
heat flux condition along the entire test section. The inlet and
outlet temperatures of bulk air were measured using a multi-
channel temperature measurement unit in conjunction with the
resistance temperature detectors (RTDs). One RTD was lo-
cated 600 mm upstream of the test section for measuring inlet
air temperature while other three RTDs were located 300 mm
downstream of the test section (around a perimeter of the tube)
for measuring outlet air temperature. Note that prior to being
4773
measured an outlet temperature, the working fluid was sub-
jected to the mixing chamber located upstream of the outlet
RTDs. Fifteen thermocouples were silver soldered to the test
tube surface (embedded in v-groove tube surface) for measur-
ing local wall temperatures. The positions of the thermocou-
ples were 0, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000,
1100, 1200, 1300 and 1400 mm from the entrance of the test
section. The mean wall temperature was determined by means
of calculation based on the reading of the Copper-Constantan
thermocouples. Pressure drop across the test section was
measured using an inclined U-tube manometer filled by the
manometric fluid having low specific gravity (SG) of 0.826 to
ensure reasonably accurate measurement of the low pressure
drop encountered at low Reynolds numbers. In the present test,
all data were taken via personal computer at steady state.
Based on the standard of ANSI/ASME [24], the measurement
uncertainties of the present works are follow as within 6%
for axial velocity, 5% for pressure and 0.5% temperature.
The uncertainties of non-dimensional parameters are within
6% for Reynolds number, 6% for Nusselt number and 8%
for friction factor.
4. Heat transfer and friction factor measurements
4.1 Nusselt number evaluation
In the experiments, air as the working fluid was tested un-
der uniform heat flux condition [22]. Heat transfer rate gained
by air is evaluated using the temperature difference across the
test section as
Qair = MCp(To-Ti). (1)
The thermal equilibrium test showed that the heat supplied
by electrical winding in the test section is 6 to 9% larger than
4774 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779
the heat absorbed by the working fluid (air).
QIV - Qair
100% 6-9% .
QIV
At the steady state, the heat transfer gained by air is as-
sumed to be equal to the convection heat transfer from the test
section:
Qair = Qconv
where
Qconv = hA(T%w - Tb )
where Qconv is a rate of convection heat transfer from the test
section and A is a heating internal surface area. T%w is an aver-
age value of the wall temperatures (Tw) lined between the inlet
and the exit of the test tube.
T%w = Tw / 15 .
Tb is an average fluid bulk temperature in the tube evaluated
from
Tb = (To+Ti)/2
where To is a mean outlet temperature obtained from three
RTDs located around a perimeter of the tube. Regarding to
Eqs. (1) and (5), an average heat transfer coefficient (h) can be
achieved from
h = MC p (To - Ti ) / A(T%w - Tb ) .
In the experiment, the local mean bulk temperatures of the
working fluid flowing into the test section are determined
from Tbx = Tbi + q&p DLx / MC p . The local and mean heat trans-
fer coefficients are calculated from
hx = q& / (Twx - Tbx )
where q& is the constant heat flux.
On the other hand, the calculation of a local heat transfer
coefficient is based on a specific local wall temperature. Nus-
selt number can be calculated using the following equation:
Nu = hD/k
where D is an inner diameter of the test tube and k is a thermal
conductivity of the working fluid.
4.2 Friction factor evaluation
The pressure drop (DP) across the test section length (L)
(2)
(3)
(4)
Fig. 3. Validation of the plain tube for Nusselt number.
was subjected to the calculation of friction factor via the fol-
lowing equation [22]:
(5)
f = (D/L)(2DP/rU2) (10)
where U is an average velocity which is calculated by dividing
the measured volumetric air flow rate by the inlet cross-
(6) sectional area (A).
The Reynolds number based on an inner diameter of the test
tube diameter can be expressed as;
Re = rUD/m. (11)
All of the thermo-physical properties (k,r, m, Cp) used for
the calculations of the dimensionless numbers (Nu, Re, Pr) are
(7) all evaluated at the bulk fluid temperature (Tb) from Eq. (7).
5. Results and discussion
5.1 Plain tube results
In the first place, the heat transfer and friction factor data of
the plain tube were collected and then compared to those from
(8) standard correlations, in order to prove the reliability of ex-
perimental apparatus and measurement techniques over the
whole range of flow conditions. Fig. 3 shows variation of
Nusselt number (Nu) in the plain tube with Reynolds number.
Apparently, the experimental Nu agreed well with those ob-
tained from Dittus and Boelter [25] with the discrepancy of
less than 6.2%. The experimental friction factors in plain tube
(9) are compared with those from Blasius correlation as shown in
Fig. 4. The friction factors in the present work were slightly
higher than the predictions within 7.2%.
5.2 Local heat transfer results
Effect of the HST-R/HST on the axial distributions of Nus-
selt numbers along the whole test tube for Re = 8,000 is dem-
 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779
Fig. 4. Validation of the plain tube for friction factor.
Fig. 5. Effect of HST-R on local Nusselt number for Re = 8000.
onstrated in Fig. 5. It can be seen that, for all types of the tape
inserts, the Nusselt number is very high at the entry region
(X/D = 0 to 5) due to the entry effect (high thickness of the
thermal boundary layer) and then gradually decreases to
nearly uniform value beyond X/D of 9.
5.3 Heat transfer results
Figs. 6 and 7 present the effect of HST-R and also HST on
heat transfer enhancement. For all cases, Nusselt number in-
creased as Reynolds number increased, reflecting the increase
of turbulence intensity. At a given Reynolds number, HST-Rs
and HST significantly enhanced heat transfer above that in the
plain tube. All HST-Rs were more efficient than HST at simi-
lar conditions. It is most likely that vortices generated by ribs
are carried through the tube by the main and swirl flows, lead-
ing to more chaotic fluid mixing and efficient disturbing ther-
mal boundary layer. Thermal boundary layer shape and thick-
4775
Fig. 6. Effect of HST-R on Nusselt number.
Fig. 7. Effect of HST-R on Nusselt number ratio.
ness continue to change. The velocity profile does not become
further shallower, whereas temperature profile becomes fur-
ther shallower. For the range studied, the average Nusselt
number of the tubes equipped with HST-Rs was higher than
that with HST and the plain tube around 9.4% and 12.7%,
respectively. The results also demonstrate that Nusselt number
increased as the rib-pitch ratios (p/D) decreased. This can be
responsible by a higher number of vortices and more consis-
tent turbulence imparted to the flow and tube wall. The aver-
age Nusselt number in the tubes with HST-Rs with the small-
est rib-pitch ratio (p/D = 1.0), was 1.8% and 5.4% higher than
those with rib-pitch ratios, p/D = 2.0, and 3.0, respectively. In
addition, Nusselt number also increased as rib-height ratios
(e/W) increased. The average Nusselt number in the tubes
with HST-Rs with the largest rib-height ratio (e/W = 1.5), was
4776 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779
Fig. 8. Effect of HST-R on friction factor.
Fig. 9. Effect of HST-R on friction factor ratio.
10.3% and 4.4% higher than those with e/W = 0.5 and 1.0,
respectively. This can be explained by the fact that the higher
rib gives more protrusion and thus causes stronger turbulent
fluctuation or eddy motion leading to better fluid mixing and
thus heat transfer.
5.4 Friction factor results
The variations of friction factor and friction ratio with Rey-
nolds number for the tubes with HST-Rs, HST and also the
plain tube are shown in Figs. 8 and 9. Friction factor consis-
tently decreased with the increase of Reynolds number. At
similar conditions, friction factors of tube fitted with HST-Rs
Fig. 10. Effect of HST-R on thermal performance factor.
and HST were dramatically higher than those in the plain tube.
This is primarily caused by flow disturbance by the inserts.
The presence of ribs on HST-Rs also generates extra distur-
bance as compared to that in case of HST, giving rise to high-
er dissipation of dynamic pressure of the fluid flow. Evidently,
the average friction factor of the tubes with HST-Rs was
found to be higher than that of the plain tube and the one with
HST around 818% and 49.9%. In addition, friction factor in-
creased with decreasing rib-pitch ratio and increasing rib-
height ratio. It is noteworthy that HST-Rs with smallest p/D =
1.0 and rib-height ratios of e/W = 1.5 and 1.0 caused dramati-
cally higher friction factor than other cases.
The mean friction factor caused by HST-Rs with the small-
est rib-pitch ratio (p/D = 1.0) was higher than those given by
given HST-Rs with p/D = 2.0, and 3.0 around 40.4% and
50.2%, respectively. The average friction factor in the tubes
with HST-Rs with the largest rib-height ratio (e/W = 1.5), was
34.2% and 11.7% higher than those with e/W = 0.5 and 1.0,
respectively. Justified by the overall results of using HST-Rs,
it was found that the inserts enhanced heat transfer at the ex-
pense of relatively higher percentage increase in friction pen-
alty, at the same Reynolds number.
5.5 Thermal performance factor
The variation of thermal performance factor (h) with Rey-
nolds number for the tubes with HST-Rs, and HST is shown
in Fig. 10. For all cases, thermal performance factor increased
with the decrease of Reynolds number. The reason is that
thermal boundary layer in laminar regime is thicker than in
turbulent regime which causes stronger eruption of the bound-
ary layer in lower Re, thus enhances higher thermal perform-
ance factor. This indicates that the use of HST-Rs for energy
saving prospect is possible at low Reynolds number. It can be
 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779 4777

Fig. 11. Comparisons between experimental and predicted data for

Nusselt number.
Fig. 12. Comparisons between experimental and predicted data for
friction factor.

observed that the tube with HST possessed thermal perform-

ance factor around average value of those of the tubes with
HST-Rs. In addition, among the HST-Rs used, although the
ones with p/D = 2 gave moderate value for both Nusselt num-
ber and friction factor, they offered the higher thermal per-
formance factor than the ones at p/D = 1 and 3, indicating
better trade-off between the improved heat transfer and in-
creased fiction. In addition, thermal performance factor con-
sistently increased as rib-height ratio of HST-Rs increased.
The maximum thermal performance factor of 1.15 in the pre-
sent study was found by the use of HST-Rs with p/D = 2, e/W
= 1.5 at Reynolds number of 6,000.

5.6 Empirical correlations

The results of the Nusselt number and friction factor for

helical screw tape coupled with rib turbulators (HST-Rs) of
varying rib-pitch ratios (p/D) and rib-height ratios (e/W) are
correlated as follows: Fig. 13. Comparisons between experimental and predicted data for
thermal performance factor.

Nu = 0.07Re0.751Pr0.4(p/D)-0.046(e/W)0.088
f = 1.072Re-0.11(p/D)-0.373(e/W)0.254
h = 6.05Re-0.202(p/D)0.078(e/W)0.047 .
Figs. 11-13 show the comparisons between the present ex-
perimental data and the present correlations. Obviously, the
present results agreed well with those obtained from the above
correlations within 4.4% for Nusselt number, 13% for fric-
tion factor and 4.2% for thermal performance factor. The
comparisons indicate that the correlations can be used to eval-
uate Nusselt number, friction factor and thermal performance
factor in the tubes with HST-R for the engineering design
application.
(12)
(13) 6. Conclusions
(14)
Augmentation of turbulent flow and heat transfer in heat
exchanger tubes by means of helical screw tape coupled with
rib turbulators (HST-Rs) with different rib-pitch ratios (p/D)
and rib-height ratios (e/W) has been investigated. The results
of HST-Rs were compared with those of the convention heli-
cal screw tape (HST). Effects of HST-Rs on Nusselt number,
friction factor and thermal performance factor were examined.
The major findings are:
(1) All HST-Rs consistently gave higher Nusselt number
and friction factor than HST, at similar conditions.
(2) Nusselt number and friction factor increased as rib-pitch
4778 K. Nanan et al. / Journal of Mechanical Science and Technology 28 (11) (2014) 4771~4779

ratio (p/D) decreased and rib-height ratio (e/W) increased. At Abbreviations

smallest p/D = 1.0, the Nusselt numbers offered by HST-Rs
with e/W = 0.5, 1.0 and 1.5 were respectively 9.7%, 15.8%, HST : Helical screw tape
and 20.7% higher than that offered by the conventional helical HST-R : Helical screw tape with rib
screw tape (HST) which were accompanied by 40.6%, 96.8%,
and 133% higher friction factor, respectively.
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Kwanchai Nanan is currently a D.Eng.
candidate in the Department of Me-
chanical Engineering at Mahanakorn
University of Technology. He received
his M.Eng. and B.Eng. degrees from
Mahanakorn University of Technology
in 2006 and 2009, respectively. Mr.
Nanan has been working at Mahanakorn
University of Technology since 2007. His research interests
include heat transfer enhancement in channels/tubes, im-
pingement jet and film jet cooling in gas turbine.
Monsak Pimsarn is currently an Assis-
tant Professor in Department of Me-
chanical Engineering, Faculty of Engi-
neering, King Mongkuts Institute of
Technology Ladkrabank, (KMITL) Thai-
land. He hold a Bachelor of Engineering
degree in Mechanical Engineering from
KMITL, a Master of Science in Me-
chanical Engineering degree from the Vanderbilt University
(Nashville, Tennessee), and a Doctor of Philosophy in Me-
chanical Engineering from University of Connecticut at Storrs.
Chinaruk Thianpong received the
B.Eng. (Mechanical Engineering) from
King Monkut's Institute of Technology
Ladkrabang (KMITL), Thailand in 1991,
MSc. (Mechanical Engineering) and
Ph.D. (Mechanical Engineering) from
University of Manchester in 1998.
Nowadays, he is a lecturer in Depart-
ment of Mechanical Engineering, KMITL. His researches are
about thermo-fluid, heat transfer and energy conservation.
Smith Eiamsa-ard is an Associate Pro-
fessor in the Department of Mechanical
Engineering at Mahanakorn University
of Technology. He received his D.Eng.
degree in Mechanical Engineering from
King Mongkuts Institute of Technology
Ladkrabang. He has been working at
Mahanakorn University of Technology
since 1996. He has co-authored more than 95 International
Journal publications. His research interests are in the topic of
heat transfer enhancement with active/passive technique, flow
visualization techniques, and computational fluid dynamics.