De La Salle University – Dasmariñas

College of Engineering, Architecture, and Technology

Mechanical Engineering Program

Mechanical Engineering Lab 1

T-MEET324LA - MEE31

PERFORMANCE EVALUATION OF A SHELL AND TUBE HEAT EXCHANGER

Experiment No. 12

Submitted by:
Barillo, John Paolo D.
Dones, Victor Lorenz E.
Escober, Christian A.
General, Paul Ryan L.

Submitted to
RENE D. RUBIO PhD, PME, OSH Consultant

GROUP No. 5

Date Submitted:
June 22, 2022
TABLE OF CONTENTS

I. Objective

II. Theory

III. List of Components

IV. Procedures

V. Safety Precautions

VI. Set up of Experiment

VII. Questions and Problems

VIII. Conclusion

IX. Recommendation

X. References
I. OBJECTIVE

1. To be able to familiarize heat exchanger unit.

2. To make a physical study on WL110 Heat Exchanger Service Unit.

II. THEORY

Heat exchangers are devices that transmit thermal energy from one medium to another.

The two streams are not in direct contact with one another. Heat transfer efficiency is required for

cost-effective procedures. As a result, depending on the needs, numerous heat exchanger types

are employed in practice.

This experimental unit can be used to investigate and compare different heat exchanger

designs. The complete experimental setup consists of two main elements: WL 110 as service and

control unit and choice of heat exchanger: Tubular heat exchanger (WL 110.01), a plate heat

exchanger (WL 110.02), shell and tube heat exchanger (WL 110.03) and jacketed vessel with

stirrer and coil (WL 110.04). Water is used as the medium.

The heat exchanger to be investigated is connected to the service unit. The hot water

flows through the heat exchanger. Part of the thermal energy of the hot water is transferred to the

cold water. Reversing the water connections changes the direction of flow and thus allows parallel

flow or counterflow operation.

The main function of the WL 110 is to provide the required cold and hot water circuits. To

do this, the service unit is equipped with a heated tank and pump for the hot water circuit,

connections for the cold water circuit, and a switch cabinet with displays and controls. A

temperature controller controls the hot water temperature. The flow in the hot water and cold

water circuit is adjusted using valves. The cold water circuit can be fed from the laboratory mains

or the WL 110.20. The measured values can be read on digital displays. At the same time, the

measured values can also be transmitted directly to a PC via USB. The data acquisition software
is included. In experiments, the typical characteristic value determined is the mean heat transfer

coefficients. The well-structured instructional material sets out the fundamentals and provides a

step-by-step guide through the experiments.

III. List of Components

Qty Unit Description

1 Set WL110 Heat Exchanger

Service Unit

IV. PROCEDURE

⇨ Make a schematic diagram / drawing of WL110 Heat Exchanger

Service Unit complete with accessories:

a. WL 110 .01 Tubular Heat Exchanger

b. WL 110 .02 Plate Heat Exchanger

c. WL 110 .03 Shell and Tube Heat Exchanger

d. WL 110 .04 Jacketed Vessel with Stirrer and Coil

V. SAFETY PRECAUTIONS

During Design

1. Make sure you have decided on appropriate design conditions for the heat exchanger:
heat exchanger type, temperature design, pressure design, material compatibility, fluid
nature, supports, gas vent, drain, and structural design. The inappropriate design will lead
to mechanical integrity problems.

2. Pay attention to the gasket material. Material selection, gasket type, and thickness have
to be matched to avoid leakage.

3. An abnormal temperature and pressure increase may happen. Design the heat exchanger
to withstand such conditions.

4. The heat exchanger shall be designed for a safe maintenance environment.

5. Overpressure can be avoided by installing a safety relief device.

6. A relatively high-temperature surface shall be covered by insulation.

7. Consider installing an alarm system

8. Grounding is very important.

9. Consider special considerations when designing a heat exchanger suppose for hydrogen
peroxide. Such heat exchangers must have an inclined construction to remove gas that
usually appears during regular operation.
 During the Operation

1. Tube plugging due to the buildup of foulants. This can cause pressure buildup inside the
heat exchanger.

2. Beware of tube leaking caused by corrosion. If the fluid on the hot and cold sides mix, a
reaction may occur. A corrosion monitoring, inspection, and leak detection are very
important.

3. If a slurry flow or contaminated liquid flow enters the heat exchanger, erosion may happen
and can cause leaking too. Install a filter to separate solid material from the liquid flow.

4. Avoid over-pressuring the heat exchanger. Do start-up and shut down operations
smoothly. Follow the SOP.

5. Keep out of a hot surface that may cause skin burn.

During Maintenance

1. Follow LOTO – lock out tag out – procedure when you will maintain a heat exchanger.
Make sure all inlet valves are already secured and tag appropriately.

2. Release pressure from the heat exchanger. Ensure that the pressure gauge indicates zero
bar.

3. Drain out hazardous chemicals from the heat exchanger.

4. Be careful when selecting chemical cleaning material for tube cleaning. Improper selection
will cause corrosion and leak.

5. If a mechanical method is used for cleaning the tube side, take care not to cause tube
defects. Mechanical cleaning can cause injury to people too.

6. Install new gasket – mainly on the head – carefully to avoid leakage. Improper installation
will lead to leakage.

7. Hydrostatic test after maintenance job is required. Be careful to do this job safely because
high pressure will be applied.
VI. SET-UP OF EXPERIMENT

1. service unit for heat exchangers

2. hot water circuit with a tank, heater, temperature controller, pump, and protection
against lack of water
3. cold water circuit from laboratory mains or water chiller WL 110.20
4. temperature controller controls the temperature of hot water
5. flow adjustable using valves
6. digital displays for 6 temperature and 2 flow rate sensors
7. water connections with quick-release couplings
8. stirrer connection with speed adjustment (WL 110.04)
9. GUNT software for data acquisition via USB under Windows Vista or Windows 7

10.
VII. QUESTIONS & PROBLEMS

Questions

1. What is a heat exchanger?

- A heat exchanger is a device that transfers heat from one medium to
another. For example, a Hydraulic Oil Cooler removes heat from
heated oil by cooling it with cold water or air.
2. What are the functions of a heat exchanger in
a. Power Plant System
- For heat exchange between hot products (produced by fuel
oxidation) and water/steam, steam-turbine power plants commonly
employ boiler tubes mounted inside a bubbling or circulating fluidized
bed.

b. Refrigeration System
● Hot Gas Bypass Valve
- Is utilized to manage the capacity of a chiller. Delivering high-
pressure, high-temperature gas into the evaporator, it creates
an artificial load.
● Liquid Solenoid Valve
- When the system is turned off, it prevents the liquid refrigerant
from migrating to the compressor.
● Process cooling
- Is a means of extracting heat from an area where it isn't
wanted (the process) and transporting it outside of a
manufacturing facility.

c. Automotive System
- With several-tube passes, most automobile heat exchangers are
comparable to shell and tube cross-flow designs. There is no
 limiting control volume for the shell instead of a defined shell
around the tubes with another regulated fluid-driven across the
tubes by a pump. The tubes are exposed to the elements and are
dependent on the weather.
- Radiators, oil coolers, and intercoolers are examples of automotive
heat exchangers, although they are not the only ones. Heat
exchangers may be used to heat or cool practically any fluid in a
vehicle. Air conditioners and heaters are examples as well,
although they are not limited to automobiles.

3. Discuss briefly the types of heat exchangers.

- The researchers discovered three different types of heat exchangers. The
first is a finned tube heat exchanger, which works by pushing gas or air
around or over the piping to cool the fluid. Shell and tube heat exchangers,
on the other hand, function by moving a hot or cold fluid or gas through a
series of tubes contained in a huge metal shell. Plate heat exchangers, also
known as gasket plate heat exchangers, circulate fluids via a sequence of
plates that are compressed side by side.
Problem Solving

1. A jet water direct contact condenser (heat exchanger) discharges water at 37oC with inlet
water at 8oC. Condenser pressure is 0.01 MPa (0.1 Bar). Calculate the kilogram of
condensing water per kilogram of exhaust steam with a quality of 80%.

𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛:

𝑊ℎ𝑒𝑟𝑒:
𝑚ℎ = 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝐻𝑜𝑡 𝑆𝑡𝑟𝑒𝑎𝑚)
𝑚𝑐 = 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟)

𝑆𝑜𝑙𝑣𝑖𝑛𝑔 𝑓𝑜𝑡 𝑡ℎ𝑒 𝑟𝑎𝑡𝑖𝑜 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑔𝑖𝑣𝑒𝑠:

𝑚𝑐 ℎ1 − ℎ2 2076 − 188.44
= =
𝑚ℎ ℎ3 − ℎ4 155.03 − 33.60

𝑚𝑐
∴ = 15.46
𝑚ℎ

𝐹𝑟𝑜𝑚 𝑡ℎ𝑒 𝑇𝑎𝑏𝑙𝑒 𝑜𝑓 𝑃𝑟𝑜𝑝𝑒𝑟𝑡𝑖𝑒𝑠 𝑜𝑓 𝑆𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑊𝑎𝑡𝑒𝑟

(𝐿𝑖𝑞𝑢𝑖𝑑 − 𝑉𝑎𝑝𝑜𝑟): 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇𝑎𝑏𝑙𝑒
 Stream Temperature Pressure Enthalpy Quality
(MPa) kJ/kg (%)

1 0.01 2076 80

2 188.44

3 8o C 33.60

4 37o C 155.03

2. A surface condenser (heat exchanger) serving 50,000 KW steam turbo generator unit
receives exhaust steam at the rate of 196,000 kg/hr. Condenser pressure is 0.0070 MPa.
Cooling water enters at 29.5oC and leaves at 37.5oC. For steam turbine condenser
design, manufacturers consider 950 Btu/lb. of steam condensed as heat given up to
cooling water.
Calculate
a. LMTD (Log Mean Temperature Difference)
b. Required quantity of cooling water in cubic meters per second.

𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛:
𝑄 = 𝑚 𝑥 𝐶𝑝 𝑥 (𝑇2 − 𝑇1)
𝑇2 − 𝑇1 (= 𝛥𝑇) = 𝑄/(𝑚 𝑥 𝐶𝑝) = 17.24 𝑥 106 /(432,101 𝑥 0.74) = 54
𝑇 ℎ𝑜𝑡 𝑖𝑛 = 118 + 54 = 172°
𝑇 ℎ𝑜𝑡 𝑜𝑢𝑡 = 118°
𝑇 𝐶𝑜𝑙𝑑 𝑖𝑛 = 29.5°
𝑇 𝐶𝑜𝑙𝑑 𝑜𝑢𝑡 = 37.5°
𝛥𝑇1 = 𝑇 ℎ𝑜𝑡 𝐼𝑛 − 𝑇 𝐶𝑜𝑙𝑑 𝑜𝑢𝑡 = 172 − 37.5 = 134.5°
𝛥𝑇2 = 𝑇 ℎ𝑜𝑡 𝑜𝑢𝑡 − 𝑇 𝐶𝑜𝑙𝑑 𝑖𝑛 = 118 – 29.5 = 88.5°

𝛥𝑇1 − 𝛥𝑇2 134.5° − 88.5° 46 46

𝐿𝑀𝑇𝐷 = ( )=( )= =
𝛥𝑇1 134.5° 𝑙𝑛 𝑙𝑛 1.52 0.418
𝑙𝑛 𝑙𝑛
𝛥𝑇2 88.5°
= 110
 3. A heat exchanger is to be designed to heat 1,118 kg/hr of kerosene from 26.5oC to 50oC.
It is to flow outside of 2.86 cm. OD and 2.53 cm. ID copper tube. The heating is to be
done by water supplied at 93.5oC which is flowing inside the tube at the rate of 1.2 kg/s.
The heat exchanger is to be insulated. Neglect the thermal resistance of copper tube.
Calculate the necessary length of heat exchanger tube for parallel and counter flow.

𝑇ℎ𝑒 𝑓𝑜𝑙𝑙𝑜𝑤𝑖𝑛𝑔 𝑣𝑎𝑙𝑢𝑒𝑠 𝑜𝑓 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑎𝑟𝑒 𝑘𝑛𝑜𝑤𝑛:

𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 812 𝑘𝑔/𝑚3

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 = 2.1 𝐾𝐽/𝑘𝑔 °𝐾

𝐹𝑖𝑙𝑚 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 738 𝑊/𝑚2 °𝐾

𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛:
𝐹𝐵𝐷:

𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐹𝑜𝑟𝑚𝑢𝑙𝑎𝑠:
𝐴 = 𝑄/(𝑈 𝑥 𝐿𝑀𝑇𝐷)
𝑄 = 𝑚 𝑥 𝐶𝑝 𝑥 𝛥𝑇𝑚
𝛥𝑇1 = 𝑇 ℎ𝑜𝑡 𝑖𝑛 − 𝑇 𝐶𝑜𝑙𝑑 𝑜𝑢𝑡 = 93.5° – 50° = 43.5°
𝛥𝑇2 = 𝑇 ℎ𝑜𝑡 𝑜𝑢𝑡 − 𝑇 𝐶𝑜𝑙𝑑 𝑖𝑛 = (93.5 – 24)° – 26.5° = 43.0°

𝛥𝑇1 − 𝛥𝑇2 43.5 − 43.0

𝐿𝑀𝑇𝐷 = =
𝛥𝑇1 43.5
𝑙𝑛 ( ) 𝑙𝑛 (
𝛥𝑇2 43.0)
∴ 𝐿𝑀𝑇𝐷 = 43.2495
VIII. CONCLUSION

To summarize, the experiment's goal of evaluating and studying the performance

of the shell and tube heat exchanger under various operating situations, as well as
performing mass and energy balance in the shell and tube heat exchanger, was met. To
compute the heat, the researchers utilized the equation Q = mCp(T2-T1).

Where m denotes mass, Cp denotes specific heat at constant pressure, and T

denotes the difference in temperature between the hot and cold sides.

Changing the heat exchanger layout or just acquiring a bigger heat exchanger will
frequently improve the equation.

IX. RECOMMENDATION

Applying to a laboratory can make the experiment much easier to visualize and
also human errors in gathering data may occur due to inaccuracy of how it is presented.
Using the right tools for making the experiment can give the researchers a good example
of how to execute the data to understand more about evaluating the performance of a
shell and tube heat exchanger.
X. REFERENCES

Turnbull & Scott. (2021, April 27). Types Of Heat Exchangers | Industrial Heat
Exchanger | Turnbull & Scott. Turnbull & Scott Engineers.
https://www.turnbull-scott.co.uk/about-us/types-of-heat-exchanger/

Hauzan, H. (2021, August 27). Heat Exchanger Safety Precautions You Should
Know. The Safety Blog on Safety Tips for the Workplace.
https://safels.com/heat-exchanger-safety-precautions/

Automotive Heat Exchangers - Thermal Systems. (n.d.). Wikidot.

http://me1065.wikidot.com/automotive-heat-exchangers

Heat Transfer and Refrigeration Basics. (2022). Plastic Technology.

https://www.ptonline.com/kc/process-cooling/basics/heat-transfer-and-
refrigeration

Ali, S. M. (2021). What are power plant heat exchangers? ResearchGate.

https://www.researchgate.net/post/What_are_power_plant_heat_exchang
ers

Thermex Heat Exchangers. (n.d.). What is a Heat Exchanger? How do Heat

Exchangers Work? Thermex. http://www.thermex.co.uk/news/blog/160-
what-is-a-heat-exchanger