THERMAL PERFORMANCE OF SERRATED PLATE INSERTS IN

CIRCULAR PIPE
1
AJIT R. SHINDE, 2YOGESH J. BHALERAO, 3NILESH B. TOTLA
1
Student, Mechanical Engineering Department, MIT Academy of Engineering, Alandi, Pune.
2
Professor, Mechanical Engineering Department, MIT Academy of Engineering, Pune.
3
Senior Assistant Professor, Mechanical Engineering Department, MIT Academy of Engineering, Pune.
E-mail: 1 ajitshinde2345@gmail.com, 2ybhalerao@maepune.ac.in, 3nbtotla@mech.maepune.ac.in.

Abstract- The heat exchangers are used to enhance heat transfer by providing high heat fluxes or heat transfer coefficient.
The second law efficiency increases and the entropy generation decreases by reducing the temperature driving force which is
caused with the increase in heat transfer coefficient. The present experimental work is carried out with copper and
aluminium serrated plate by varying groove (slot) thickness from 6mm to 8mm and by varying thickness of plate from 3mm
to 5mm respectively. The inserts when placed in the path of the flow of the fluid, create a high degree of turbulence resulting
in an increase in the heat transfer rate and the pressure drop. The work includes the determination of friction factor and heat
transfer coefficient for various inserts with varying thickness and different materials. The results of varying thickness in
serrated plates with two materials are compared with the smooth tube and found that copper with 5mm thick and 6mm
serrated slot has optimum results in terms of heat transfer coefficient and friction factor.6mm slot and 5mm plate thickness
copper shows higher Nusselt number of 60% to 76% and lesser friction factor by 39% as compared to without inserts.

Keywords- Enhancement efficiency, heat transfer, serrated plate inserts, turbulent; swirling, pressure drop.

I. INTRODUCTION intensity. The swirl induced tangential flow velocity

Heat exchangers are mostly used devices in many
areas of the industries. Hence, the using of high
performance heat exchangers is very important for
saving energy. A lot of methods are applied to
increase thermal performance of heat transfer devices
such as treated surfaces, rough surfaces, swirling flow
devices, coiled tubes, and surface tension devices [1].
Several heat transfer enhancement techniques are
utilized in order to improve the heat transfer or
thermal performance of heat exchangers. The goal of
the heat transfer enhancement is to provide high heat
fluxes or heat transfer coefficient. The second law
efficiency increases and the entropy generation
decreases by reducing the temperature driving force
which is caused with the effect of heat transfer
coefficient increase. Generally, heat transfer
enhancement techniques can be divided into two
groups (passive and active techniques).
The passive techniques have been usually preferred
by many researchers since no additional external
power is required as extended surfaces, rough
surfaces and swirl flow devices. Coiled wire insert is
one of the passive heat transfer enhancement
techniques, which is extensively used in various heat
transfer applications such as, air conditioning and
refrigeration systems, heat recovery processes, food
and dairy processes, chemical process plants. The
wire coil is quite simple to manufacture, to insert and
remove from the tube which, therefore, justifies its
usage in heat transfer enhancement. Coiled wire,
twisted tape or other swirl flow devices inserted into
a flow provide swirling flow and periodic
redevelopment of the boundary layer, increase the
effective heat transfer area and the turbulence
component causes improved fluid mixing between the
tube core and the wall region nearby. On the other
hand, the swirl induced heat transfer enhancement
brings along inevitable shear stress and pressure loss
in coiled wire or twisted tape inserted tube. For a long
time, many researchers have been carried out
concerning the effect of wire coil inserts on the heat
transfer and pressure drop.
II. LITERATURE SURVEY
Sarma et al[3]gave generalized correlations to predict
friction factor and convective heat transfer coefficient
in a tube fitted with twisted tapes for a wide range of
Reynolds number and Prandtl number. The
contribution to thermal performance of the
conventional, short-width and center-cleared twisted
tapes was studied numerically [2]. Configuration
optimization of regularly spaced short-length twisted
tapes in a circular tube for turbulent heat transfer was
carried out by Wang et al. [4]by using computational
fluid dynamics (CFDs) modeling. Eiamsa-ard et al.
[5]presented experimental study on convective heat
transfer in a circular tube with short-length twisted
tapes inserted under uniform heat flux. Akhavan-
Behabadi et al. [6]conducted some experiments to
analyze effects of twisted tapes on heat transfer
enhancement and pressure drop in horizontal
evaporators. They selected R-134a as working fluid.
Heat transfer and friction factor of CuO/water
nanofluid and water were experimentally investigated
in circular tube equipped with modified twisted tapes
has alternate axis [7–9]. Eiamsa-ard et al.
[10]performed experimental works on heat transfer
and friction factor characteristics in a double pipe
heat exchanger fitted with twisted tape elements.

Proceedings of SARC International Conference, 26th March, 2017, Pune, India, ISBN: 978-93-85832-29-1
7
 Thermal Performance of Serrated Plate Inserts in Circular Pipe
They made their analysis for both continuously
placed twisted tape and twisted tape placed with
various free spaced in circular tube.
The heat transfer augmentation and pressure drop
during condensation of HFC-134a in a horizontal
tube fitted with twisted tapes were experimentally
analyzed. Jaisankaret al. experimentally examined the
heat transfer, friction factor and thermal performance
caused by twisted tape for solar water heater. Twist
ratio, space ratio, tape width, rod-diameter and phase
angle effects on heat transfer and pressure drop were
analyzed experimentally in a circular tube fitted with
regularly spaced twisted tape elements [10]. Naphon
[08] also made experiments by using conventional
twisted tape inserts in horizontal double pipe. Ferroni
et al. conducted some experiments in circular tube
equipped with physically separated, multiple, short-
length twisted tapes. Laminar convective heat transfer
enhancement in twisted tape inserted tube was
discussed experimentally by Sarma et al.. In some
studies, researchers focused the thermal effects of
twisted tape inserts in modified tube instead of
smooth tube, for example; Thianpong et al. examined
heat transfer enhancement in a dimpled tube with a
twisted tape swirl generator inserted. They also
presented the empirical correlations based on the
experimental results of their study for prediction the
Nusselt number and friction factor for Reynolds
number from 12,000 to 44,000.Although many
theories has been devised over past few years, there
exist certain limitations and technological gaps. In an
attempt to overcome some of the limitation and
explore possibility of alternate approach to calculate
the temperature of serrated plates, a method has been
proposed. The following were the aims and objectives
of the research being conducted during the study;
1. To investigate the effect of various thickness
width and pitches of copper and aluminium
plate inserts on heat transfer rate.
2. To correlate theoretical and experimental
values of heat transfer coefficient, Nusselt
number, friction factor for copper and
aluminium.
3. To find out the optimum result of Nusselt
number with minimum pressure drop for that
insert.
EXPERIMENTATION:
Fig.A Experimental set up for forced convection
Proceedings of SARC International Conference, 26th March, 2017, Pune, India, ISBN: 978-93-85832-29-1
8
Specifications of set up:
1 Inner diameter of pipe = (do) = 0.025 m.
2 Outer diameter of pipe = (di) = 0.028 m.
3 Length of test section L = 0.5 m.
4 Capacity of blower = 1 h.p.
5 Diameter of orifice(d) = 0.014m.
6 Range of Dimmerstat = 0 to 5 amp. 0-480V
ac.
7 Temperature indicator = 0 to 300 0C.
8 PR-IN and PR-OUT = Pressure gauge at
start and end of the test pipe. 0 to 2 kg/cm2
9 Calibrated for chromel alumel
thermocouple.
10 Voltmeter = 0-480 V; ammeter 0-5 amp.
Nichrome wire heater wound in test pipe
(band type heater).
The literature that has been discussed above deals
with active as well as passive techniques used for
heat transfer augmentation, but maximum researchers
have used passive technique as it doesn’t require any
external agency for heat enhancement, hence it is
advantageous over the active techniques thus giving
ample of room for experimental studies.
The slot has been made on copper and aluminum
inserts at 3mm and 5mm plate. The plate is 3mm and
5mm thick and the slots are of 6mm and 8mm width.
The amount of material removed will be 1.0mm and
2.5mm respectively. The arrangement has been made
in such a way that when the air enters in heat
exchanger due to geometrical arrangements on plate
the air will move in wavy form. This waves will
create a great degree of turbulence and as the
turbulence will increase it will increase the heat
enhancement by increasing heat transfer coefficient.
The material is in solid form although it will increase
the pumping power but due to the geometrical
arrangements on plate the comparative heat
enhancement will also be considerable.
III. METHODOLOGY
Table: Sample observation table
qair = m Cpair (To-Ti) = ΔVI-Qloss (1)
Where,
To and Ti are the temperatures at outer and inner wall
of test pipe.
V= Voltage supplied by the heater.
I = the current supplied to the test pipe.
 Thermal Performance of Serrated Plate Inserts in Circular Pipe

The heat provided by the electrical cable in the test This equation is used to find friction factor called as
tube is about 3 to 4% higher than the heat absorbed Nikuradse equation for rough surface i.e. with inserts.
by the air for the thermal equilibrium test because of [2]
the convection and radiation heat losses (Qloss) from The actual pressure drop is calculated with the help of
the test section to the surroundings. Therefore, only pressure gauge at both the ends of test pipe and the
the heat transfer rate absorbed by the air is taken into friction factor is calculated from the formula given
consideration for the convective heat transfer below:
coefficient calculation. ρ
ΔP= (12)
q=π (2) Where,
ΔP= pressure difference at both ends of test pipe.
The procedures for calculating the various parameters L= length of test pipe.
for with and without inserts are given below. The D= Inner diameter of pipe.
experimentation was done at constant heat supply of The experimental Nusselt numbers are calculated for
60V; hence the calculations are done at constant heat smooth as well as for rough surfaces are given below:
supply. An sample observation table is shown below ( )
to understand the parameters need to be observed Nu = . (13)
( [ . ])
during experimentation.
This equation is called as Gnielieski equation to find
Where, theoretical and actual Nusselt number for smooth and
T1 to T4 are the surface temperatures rough pipe. [2]
Ta andT5 are the ambient temperature and outlet Where,
temperature. fr = friction factor for rough surface
hw is manometer difference in cm. Nu = Nusselt number
( ) Pr = Prandtl number
Avg. Surface Temp.= (3) The overall enhancement efficiency is expressed as
( )
Avg. Temp of air= (4) the ratio of the Nusselt number of an enhanced tube
with conical ring insert to that of a smooth tube, at a
∗ ∗ ∗ρ
Air volume flow rate Qa = a0* (5) constant pumping power is introduced by Webb [19].
ρ
⁄ /
Where, PEC= η = ( | / ) /
(14)
a0= cross sectional area of orifice. The actual photographs of serrated plate inserts of
Mass flow rate m= Qa*ρa (6) various pitches and thickness are shown below from
h= ( )∗(
(7) Fig. (a) to (d).
)
Where,
h = heat transfer coefficient.
Ts = surface temperature
The Reynolds number for the fluid is defined by, Re
= υ (8)
Where,
V= velocity of the fluid.
ν = Kinematic viscosity of the fluid.
For internal flows if Reynolds (Re) number exceeds
by 2000 then the flow is turbulent. After the flow is
decided i.e. laminar or turbulent then the Nusselt Fig. (a): Aluminium inserts of 6mm width with 20mm pitch for
number can be calculated. The theoretical Nusselt 3mm and 5mm thick plate
number is calculated below without considering
friction which is theoretical Nusselt number and then
calculated by considering friction which will be
experimental Nusselt number.
Nuth = 0.023*(Re)0.8* (Pr)0.4 (9)
This equation is called Dittus-Boettier equation.
fs = (0.790 lnRe-1.64)2 (10)
This equation is used to find friction factor called as
Petukhov equation for smooth surface. [2]
Where,
fs= Friction factor for smooth tube .
Re= Reynolds number.
ε
.
= −0.86ln [ .
+ ] (11)
√ √ Fig. (b): Copper inserts of 6mm width with 20mm pitch for
3mm and 5mm thick plate.

Proceedings of SARC International Conference, 26th March, 2017, Pune, India, ISBN: 978-93-85832-29-1
9
 Thermal Performance of Serrated Plate Inserts in Circular Pipe

0.13
Aluminium
0.12 3mm thick
and 8mm
0.11 slot
Aluminium
0.1 5mm thick
and 6mm
0.09
slot

Fr
0.08 Aluminium
5mm thcik
Fig.(c): Aluminium inserts of 8mm width with10mm pitch for 0.07 and 8mm
3mm and 5mm thick plate. slot
0.06 without
inserts
0.05

0.04
4500 9500 14500
Re
Fig 2.Comparison of Friction factor Vs Re Aluminium

From above graph, Fr Vs Re it is observed

thataluminium plate 3mm thick and 8mm slot has
lesser friction factor in the range of 0.12 to 0.095 with
Fig. (d): Copper inserts of 8mm width with 10mm pitch for approx. 7000Re to 13000Re hence it found optimum.
3mm and 5mm thick plate.

IV. RESULTS AND DISCUSSIONS 165

copper
120 3mm thick
and 6mm
145
slot
110 without
inserts copper
3mm thick
125 and 8mm
100
slot
Aluminiu
m 3mm copper
90
Nu

105 5mm thick

thick and
Nu

6mm slot and 6mm

80 slot
Aluminiu
85 copper 5m
m 3mm
thick and thick and
70 8mm slot
8mm slot
Aluminiu 65
60 m 5mm without
thick and inserts
6mm slot 45
50
4000 9000 14000 4500 9500 14500
Re
Re Fig 3. Comparison of Nu Vs Re for Copper Inserts
Fig 1. Comparison of Nu Vs Re for Aluminium Inserts
From above graph Nu Vs Re it is been observed that
From above graph Nu Vs Re it is observed that plate plate of copper 5mm thick and 8mm slot has greater
of aluminium 3mm thick and 8mm slot has greater nusselt number in the range of 90 to 150 with approx
nusselt number in the range of 79 to 115 fromapprox. 7000Re to 13000Re hence found optimum.
7000Re to 13000Re hence it is found to be optimum.

Proceedings of SARC International Conference, 26th March, 2017, Pune, India, ISBN: 978-93-85832-29-1
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 Thermal Performance of Serrated Plate Inserts in Circular Pipe

0.115 may leads to better design of serrated plates with

different thickness which will be helpful for serrated
copper
0.11 plates to be used as a commonly used different
3mm
inserts. Other possible modifications are as listed
thick below:We can reduce number of thickness to width
0.105 and distance to get more optimum value.Experiments are
6mm also possible with varying the thick of serrated
0.1 slot plates.We can try some modification in the geometry
Fr

0.095 copper of serrated plates with the help of CFD analysis.We

3mm can try the same geometry with different materials
thick and compare the results with the existing material.
0.09
and
8mm CONCLUSION
0.085
slot
The results obtained from the experiment which are
0.08 discussed above are concluded below to find an
6000 8000 10000 optimum insert as compared to the other inserts to be
Re 12000 14000
used for this experimental set up.
Fig 4.Comparison of friction factor Vs Re for Copper Insert
We observe that with an increase in the Reynolds
number (Re) ranging from 6700 to 13000, the heat
From above graph, Nu Vs Re it is been observed that
transfer coefficients increases for Serrated Plates
plate of copper 3mm thick and 6mm slot has lesser
whereas the friction factor decreases.
friction factor in the range of 0.10 to 0.091 with
The 6mm slot and 5mm plate thickness copper
approx 7000Re to 13000Re hence found optimum.
shows higher Nusselt number of 60% to 76% and
lesser friction factor by 39% as compared to without
inserts.
160 Copper Vs
REFERENCES
150
Aluminium Alumi
nium
3mm [1] S. Liu, M.Sakr , “A comprehensive review on passive
heat transfer enhancements in pipe exchangers“
140 thick
[2] Sarma ,“Heat transfer coefficients with twisted tape
and inserts”, 2003.
6mm [3] Manglik R.M and Bergles A.E, 1992, “Heat transfer
130 slot enhancement and pressure drop in viscous liquid flows in
Alumi isothermal tubes with twisted-tape inserts”, Heat and Mass
120 nium Transfer, Vol. 27, No. 4, pp. 249-257
3mm [4] M.A. Akhavan-Behabadi, R. Kumar, A. Mohammadpour,
Nu

110 thick M. Jamali-Asthiani, Effect of twisted tape insert on heat

transfer and pressure drop in horizontal evaporators for the
and flow of R-134a, International Journal of Refrigeration 32
100 8mm (2009) 922–930.
slot [5] Chang S.W, Yang T.L, Liou J.S, 2007. “Heat transfer and
90 Alumi pressure drop in tube with broken twisted tape insert”,
nium Experimental Thermal and Fluid Science, Vol. 32, No. 2,
5mm pp. 489–501.
80 thick [6] Saha S.K and Mallick D. N, “Heat transfer and pressure
drop characteristics of laminar flow in rectangular and
and
70 square plain ducts and ducts with twisted-tape inserts”,
6mm Transactions of the ASME, Vol. 127, 2005.
slot [7] Rahimi .M, Shabanian S.R., Alsairafi A.A., “Experimental
60 and CFD studies on heat transfer and friction factor
characteristics of a tube equipped with modified twisted
6000 11000 16000 tape inserts”, Chemical Engineering and Processing, Vol.
Re
48, 2009, pp. 762–770
Fig 5. Comparison of Nu Vs Re for all Inserts [8] Ozechyan and Siebel Gunes, “Heat transfer enhancement
in a tube with equilateral triangle cross sectioned”,
From above graph Nu Vs Re it is been observed that Experimental fluid science, 2009.
plate of copper 5mm thick and 8mm slot has greater [9] Al-Fahed S, and Chakroun W, 1996, “Effect of tube -tape
clearance on heat transfer for fully developed turbulent
nusselt number in the range of 90 to 150 with approx flow in a horizontal isothermal tube”, Int. J. Heat Fluid
7000Re to 13000Re hence it is found to be optimum. Flow, Vol. 17, No. 2, pp. 173-178.
[10] P.K. Sarma, P.S. Kishore, V. Dharma Rao, T.
FUTURE SCOPE Subrahmanyam, A combined approach to predict friction
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work. So, serrated plates are not an exception. This

Proceedings of SARC International Conference, 26th March, 2017, Pune, India, ISBN: 978-93-85832-29-1
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 Thermal Performance of Serrated Plate Inserts in Circular Pipe
[11] Y. Wang, M. Hou, X. Deng, L. Li, C. Huang, H. Huang,
G. Zhang, C. Chen, W. Huang, Configuration optimization
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modeling.
[12] S.C. Thianpong, P.Convective heat transfer in a circular
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Communications in Heat and Mass Transfer 36 (2009)
365–371.
[13] K. Wongcharee, S. Eiamsa-ard, Enhancement of heat
transfer using CuO/water nanofluid and twisted tape with
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[14] S. Eiamsa-ard, P. Promvonge, Performance assessment in
a heat exchanger tube with alternate clockwise and
counter-clockwise twisted-tape inserts, International
Journal of Heat and Mass Transfer 53 (2010) 1364–1372.

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