Heat Transfer

Lab Report

Experiment 2: Study of Characteristics of Double Pipe

Heat Exchanger.
Instructor: Mr. Ammar Ahmad

Name: Muhammad Farhan Saleem

Roll #: 04-3-1-024-2017

Group #: G 6

Date of Performance: June 06, 2021

Department of Mechanical Engineering

Pakistan Institute of Engineering & Applied Sciences,
 Nilore, Islamabad, Pakistan.

Table of Contents
1 Abstract...............................................................................................................3

2 Learning Objectives..............................................................................................3

3 Introduction.........................................................................................................3

4 Experimental Setup..............................................................................................4

5 Theory..................................................................................................................5

5.1 Heat Exchanger Analysis............................................................................................6

5.2 Log Mean Temperature Difference (LMTD)...............................................................8

6 Procedure...........................................................................................................11

7 Observation and Calculations.............................................................................11

8 Precautions........................................................................................................13

9 Result and Discussion.........................................................................................13

List of Figures
Figure 3-1 Types of heat exchangers – concentric tube (a) parallel flow (b) counter flow; (c) shell and tube
(d) cross flow....................................................................................................................................................4
Figure 4-1 Schematic diagram of experimental facility...................................................................................5
Figure 5-1 Temperature differences between hot and cold process streams..................................................9

2
1 Abstract
The purpose of this experiment is to measure the effectiveness, NTU and overall heat
transfer coefficient in a double pipe heat exchanger in two arrangements (series and
parallel flow). Different characteristics of double pipe heat exchanger is studied. Heat
loss by the hot fluid and the heat gain by the cold fluid along with their overall transfer
coefficient were calculated. The relationship between LMTD and the heat transfer were
studied by plotting graph. The main source of error can be due to the insulation.

2 Learning Objectives
i. The students will learn to evaluate the performance characteristics of a heat
exchanger
ii. Difference in the performance of heat exchanger in parallel and counter flow
arrangement will be studied

3 Introduction
The technology of heating and cooling of systems is one of the most basic areas of
mechanical engineering. Wherever steam is used, or wherever hot or cold fluids are
required we will find a heat exchanger. They are used to heat and cool homes, offices,
markets, shopping malls, cars, trucks, trailers, airplanes, and other transportation systems.
They are used to process foods, paper, petroleum, and in many other industrial processes.
They are found in superconductors, fusion power labs, spacecrafts, and advanced
computer systems. The list of applications, in both low- and high-tech industries, is
practically endless.

Heat exchangers are typically classified according to flow arrangement and type of
construction. In this introductory treatment, we will consider three types that are
representative of a wide variety of exchangers used in industrial practice. The simplest
heat exchanger is one for which the hot and cold fluids flow in the same or opposite

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directions in a concentric-tube (or double-pipe) construction. In the parallel-flow
arrangement of Figure 2.1a, the hot and cold fluids enter at the same end, flow in the
same direction, and leave at the same end. In the counter flow arrangement, Figure 2.1b,
the fluids enter at opposite ends, flow in opposite directions, and leave at opposite ends.
A common configuration for power plant and large industrial applications is the shell-
and-tube heat exchanger, shown in Figure 2.1c. This exchanger has one shell with
multiple tubes, but the flow makes one pass through the shell. Baffles are usually
installed to increase the convection coefficient of the shell side by inducing turbulence
and a cross-flow velocity component. The cross-flow heat exchanger, Figure 2.1d, is
constructed with a stack of thin plates bonded to a series of parallel tubes. The plates
function as fins to enhance convection heat transfer and to ensure cross-flow over the
tubes. Usually, it is a gas that flows over the fin surfaces and the tubes, while a liquid
flows in the tube. Such exchangers are used for air-conditioner and refrigeration heat
rejection applications.

Figure 3-1 Types of heat exchangers – concentric tube (a) parallel flow (b) counter flow; (c) shell and
tube (d) cross flow

4
4 Experimental Setup
The objectives of the heat exchanger experiments are achieved through the use of a bench
mounted double-pipe heat-exchanger unit installed in MEL PIEAS. The schematic of the
experimental facility is shown in Figure 2.2. The unit consists of two passes which will
be used during the experiment. The hot fluid flows in the inner tube, while the cold in
outer tube. The cold fluid is provided from overhead water tank while hot fluid is
provided by means of a water bath. It is important that water at constant temperature is
provided to both fluid circuits. Two temperature gauges are available for both the hot and
cold fluid temperature measurements. The flow rates of hot and cold fluids are measured
using rotameters, connected to the inner and outer tubes. Notice that the measurements
would be taken for temperatures and flow rates for both (a) parallel and (b) counter-flow
arrangements. It is very important that the water flow through the tubes reaches stable
and steady state conditions before recording the following parameter for both parallel and
counter flow conditions.

Figure 4-2 Schematic diagram of experimental facility

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5 Theory
In theory we will discuss the heat exchanger analysis and the LMTD approach.

5.1 Heat Exchanger Analysis

The concept of overall heat transfer resistance or coefficient that you were introduced
earlier in your heat transfer course, if we apply this concept to a, for example, double-
pipe heat exchanger, the total resistance is the sum of the individual components; i.e.,
resistance of the inside flow, the conduction resistance in the tube material, and the
outside convective resistance, given by

1 1 1
Rtotal = + +
A i hi A ln k Ao ho (Eq. 1)

where subscripts i and o refer to inner and outer heat-transfer surface areas, respectively, t
is the wall thickness, and is the logarithmic mean heat transfer area, defined as

( A o − Ai )
A ln =
Ao
ln
( Ai ) (Eq. 2)

The total heat transfer resistance can be defined in terms of overall heat transfer
coefficient based on either outer or inner areas, as long as the basis is clearly spelled out.
For example, based on outer area, we have

1 A tA 1
= A o Rtotal= o + o +
Uo Ai hi A ln k ho (Eq. 3)

which after simplifying yields the overall heat transfer coefficient based on inner and
outer areas, respectively as [1]

1
Ui=
1 D i ln ( D o / D i ) Di
+ +
hi 2k D o ho (Eq. 4)

6
 1
U o=
Do D o ln ( D o / D i ) 1
+ +
Di h i 2k ho (Eq. 5)

where the inner and outer heat-transfer areas, as well as the wall thickness, and the
logarithmic mean heat transfer area, in terms of tube inner and out diameters and length
L, are given, respectively, as

A i =πD i L (Eq. 6a)

A o =πDo L (Eq. 6b)

D o −Di
t=
2 (Eq. 6c)

π ( D o −D i ) L
A ln =
Do
ln
( )
Di
(Eq. 6d)

We note from the above equations that if the wall thickness is negligible, for example, in
thin tube heat exchangers or the thermal conductivity of the tube material is very high,
the conduction resistance through the tube may be neglected in Equations (4.4) and (4.5)
to give

1 1 1 1
≈ = +
U i U o hi ho (Eq. 7)

The convection coefficients for the inlet and outlet side of the heat exchanger tube can be
estimated using empirical correlations appropriate for the flow geometry and conditions.
For the double pipe heat exchanger in MEL PIEAS such a correlation is given as

f
Nu=
( 8 )(
Re −1000 ) Pr
h

1 2
1+ (12 . 7 ) ( ) ( Pr −1 )
f 2 3
8 (Eq. 8)

Where

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 −2
f =( 0. 76 ln ( Rew ) −1 .64 )
(Eq. 9)

Prandtl number is given as

Cpμ
Pr=
k (Eq. 10)

Here Re represents Reynolds number given as

ṁ HD
Re=
A μ( ) (Eq. 11)

There are two types of Reynolds number, one based on wetted perimeter called wetted
Reynolds number Rew and other based on heated perimeter called heated Reynolds
number Reh. These perimeters appear in definition of Hydraulic Diameter HD.

4A
HD=
P (Eq. 12)

2.4.2 Heat Transfer

The general heat exchanger equation is written in terms of the mean-temperature
difference between the hot and cold fluid, ΔTm as

q̇=UA ΔT m (Eq. 13)

This equation, combined with the First Law equations, defines the energy flows for a heat
exchanger. It can be expressed in terms of the temperature change of the hot and cold
fluids, as

q̇=−( ṁC p ) h ΔT h =−Ċ h ΔT h =Ċ c ΔT c

(Eq. 14)

where Ċ h and Ċ o are the hot and cold fluid capacitance rates, respectively.

5.2 Log Mean Temperature Difference (LMTD)

Heat flows between the hot and cold streams due to the temperature difference across the
tube acting as a driving force. As seen in Fig. 2, the difference will vary with axial

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location so that one must speak in terms of the effective or integrated average
temperature differences.
The form of the average temperature difference, ΔTm, may be determined by
applying an energy balance to differential control volumes (elements) in the hot and cold
fluids. As shown in Fig. 2, for the case of parallel flow arrangement, each element is of
length dx and the heat transfer surface area is dA. It follows for the hot and cold fluid as
[1-3]

d q̇=−Ċh dT h=Ċ c dT c (Eq. 15)

The heat transfer across the surface area dA may be expressed by the convection rate
equation in the differential form as

d q̇=UdAdT (Eq. 16)

where dT = Th - Tc is the local temperature difference between the hot and cold fluids.

Figure 5-3 Temperature differences between hot and cold process streams

To determine the integrated form of Equation 16, we begin by substituting Equation 15

into the differential form for the temperature difference,

d ( ΔT )=d ( T h −T c )
(Eq.1 7)

to obtain

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 2 A
d ( ΔT )
∫ ΔT =−U Ċ1 + Ċ1 ( )∫ dA
1 h c 0 (Eq. 18)

ΔT 2 1 1
ln
( )
ΔT 1
=−UA +
Ċ h Ċ c ( ) (Eq. 19)

Substituting Ċ h and Ċ c from the fluid energy balances, Equations 15 and integrating,
we get after some manipulation,

( ΔT 2 −ΔT 1 )
Q=UA
ΔT 2
ln
( )
ΔT 1
(Eq. 20)

Comparing the above expression with Equation 13, we conclude that the appropriate
mean temperature difference is the log mean temperature difference, ΔTlmtd. Accordingly,
we have

( ΔT 2 −ΔT 1 ) ( ΔT 1− ΔT 2 )
ΔT m= ΔT lmtd = =
ΔT 2 ΔT 1
ln
( )
ΔT 1
ln
( )
ΔT 2
(Eq. 21)

Where

ΔT 1 =( T h ,i −T c , i )
(Eq. 22)

ΔT 2 =( T h , o−T c , o )
(Eq. 23)

A similar derivation can be shown for counter-flow heat exchangers; however, the
temperature difference as shown in Figure 2, will be

ΔT 1 =( T h ,i −T c , o )
(Eq. 24)

ΔT 2 =( T h , o−T c ,i )
(Eq. 25)
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As discussed above, the effective mean temperature difference calculated from this
equation is known as the log mean temperature difference, frequently abbreviated as
LMTD, based on the type of mathematical average, which it describes. While the
equation applies to either parallel or counter flow, it can be shown that ΔTm will always

be greater in the counter flow arrangement.

6 Procedure

1. Set the flows rate at the lowest (stable) reading and then monitor the
difference between the inlet and outlet temperatures for both hot and cold
water until a steady state is established.

2. Measure the temperature difference for both hot and cold flows.

3. Change the cold-water flow, each time repeating (1) and (2) above.

4. Repeat the above sequence by raising the hot-side water flow rate.

7 Observation and Calculations

Inner diameter of Tube = Di,t = 13 mm
Outer diameter of Tube = Do,t = 16 mm
Average diameter of Tube = Dav,t = 14.5 mm
Inner diameter of Pipe = Di,s = 26 mm
Hot side flow rate = Qh = 0.54 m3/s
Table 3-1 Observations and calculations

Parameter Parallel-flow Counter-flow

Hot fluid Cold Fluid Hot fluid Cold Fluid
1. Cold side flow rate = Qc = 8.33E-05m3/s
Inlet temperature (°C) 66.1 18.9 64.4 18.9
Outlet temperature (°C) 58.9 36.7 57.8 41.1
Average temperature (°C) 62.5 27.8 61.1 30
Density at avg. temp (kg/m3) 984.66 997.62 984.66 997.62
Sp. heat at avg. temp (kJ/kg. K) 4183 4180 4177 4174
Volume flow rate (m3/sec) 0.000255 0.000083 0.000255 0.000083

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 Parameter Parallel-flow Counter-flow
Hot fluid Cold Fluid Hot fluid Cold Fluid
Mass flow rate (kg/sec) 0.25 0.08 0.25 0.08
Thermal Capacitance rate, m.Cp (W/K) 0.6499 0.6 0.6499 0.6
Heat transfer rate (kW) 7581 6177 6987 7711
Average heat transfer rate (kW) 6879 7349
Nusselt number using Eq 8 325.03 63.44 324.85 63.41
Heat transfer coefficient (kJ/m2. K) 14568.11 3315 14559.91 3313
Overall heat transfer coefficient
2700 2699
(kJ/m2. K)
ΔT 1 (°C) 29.4 5.6
ΔT 2 (°C) 4.4 21.1
LMTD 15.4 12.7
Length of the heat exchanger (m) 3.63 4.72
2. Cold side flow rate = Qc = 0.000166667 m3/s
Inlet temperature (°C) 60.55 17.77 61.6 16.11
Outlet temperature (°C) 53.33 28.88 53.3 30
Average temperature (°C) 56.94 23.33 57.5 23.05
Density at avg. temp (kg/m3) 984.66 997.62 984.66 997.62
Sp. heat at avg. temp (kJ/kg. K) 4183 4180 4177 4174
Volume flow rate (m3/sec) 0.00002548 0.0001667 0.0002548 0.000167
Mass flow rate (kg/sec) 0.25 0.166 0.25 0.166
Thermal Capacitance rate, m.Cp (W/K) 0.6449 0.6 0.6449 0.6
Heat transfer rate (kW) 7581 7722 8734 9639
Average heat transfer rate (kW) 7651 9186
Nusselt number using Eq 8 325 119.85 324.84 119
Heat transfer coefficient (kJ/m2. K) 14568 6262 14560 6259
Overall heat transfer coefficient
4379 4377
(kJ/m2. K)
ΔT 1 (°C) 25 13.887
ΔT 2 (°C) 6.667 19.44
LMTD 14.98 16.59
Length of the heat exchanger (m) 2.55 2.77
3. Cold side flow rate = Qc = 0.00025m3/s
Inlet temperature (°C) 60 15.6 59.4 16.1
Outlet temperature (°C) 48.5 26.7 48.9 26.7
Average temperature (°C) 55.3 208 54.2 21.4
Density at avg. temp (kg/m3) 984.66 997.62 984.66 997.62
Sp. heat at avg. temp (kJ/kg. K) 4183 4180 4177 4174
Volume flow rate (m3/sec) 0.00025 0.00025 0.00025 0.00025
Mass flow rate (kg/sec) 0.25 0.25 0.25 0.25
Thermal Capacitance rate, m.Cp (W/K) 0.6449 0.6 0.6449 0.6
Heat transfer rate (kW) 9913 11004 11064 10988
Average heat transfer rate (kW) 10459 10459 11026 11026
Nusselt number using Eq 8 325 170.74 324 170
Heat transfer coefficient (kJ/m2. K) 14568 8921 14559 8916
Overall heat transfer coefficient 5533.04 5530.7

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 Parameter Parallel-flow Counter-flow
Hot fluid Cold Fluid Hot fluid Cold Fluid
(kJ/m2. K)
ΔT 1 (°C) 26.4 16.1
ΔT 2 (°C) 6.7 19.4
LMTD 15.7 17.8
Length of the heat exchanger (m) 2.65 2.47

8 Precautions
 Never close all four valves of the setup, it might damage pump
 Wait for at least 15 minutes

9 Result and Discussion

This experiment was conducted on a double pipe heat exchanger in both parallel and
counter flow configuration. By measuring the temperature at the inlet and outlet of both
pipes, we find different parameters like heat loss, Reynold number Nusselt number, and
heat transfer coefficient. We can also calculate the log mean temperature difference and
average heat transfer.

The experimental values for different parameters differ from the actual values provided in
the literature. It may be due to the limitations and errors in this experiment. After
conducting this experimental calculation, we conclude that the heat transfer in the
counterflow configuration is greater than the parallel flow.

The experimental values for different parameters differ from the actual values provided in
the literature. It may be due to the limitations and errors in this experiment. After
conducting this experimental calculation, we conclude that the heat transfer in the
counterflow configuration is greater than the parallel flow. Further, the heat transfer
losses can be reduced by minimizing wasteful heat losses by using proper insulations.

Possible sources of error in this experiment can be due to old and rusty heat exchanger
apparatus, which increases heat losses. Also, the temperature gauges had some limitations

13
and were old. They also had backlash errors. Taking the reading before allowing it to
arraign steady-state also produces errors in the final reading.

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