A DISSERTATION REPORT

ON

“EXPERIMENTAL INVESTIGATION OF HEAT TRANSFER

PERFORMANCE OF MATRIX COIL WIRE INSERTS ”
SUBMITTED TO

UNIVERSITY OF PUNE, PUNE

IN THE PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF THE DEGREE
OF

MASTER OF ENGINEERING
(MECHANICAL- HEAT POWER)
BY

P. B. MALWADKAR
EXAM NO:

UNDER THE GUIDANCE OF

Prof. LALIT S. PAWAR

DEPT. OF MECHANICAL ENGINEERING

DHOLE PATIL COLLEGE OF ENGINEERING, PUNE
UNIVERSITY OF PUNE
2013-2014
 DHOLE PATIL COLLEGE OF ENGINEERING

Affiliated to University of Pune

Certificate
This is to certify that the Dissertation Work Entitled

“EXPERIMENTAL INVESTIGATION OF HEAT TRANSFER

PERFORMANCE OF MATRIX COIL WIRE INSERTS”
Submitted by

Mr. Malwadkar Prashant B.

Student of M.E Mechanical Engineering (Heat Power) during the academic year 2013-14
This report embodies the work carried out by the candidate, towards the partial fulfillment of
Master Degree Course in Mechanical Engineering (Heat Power) conferred by University of
Pune.

PROF. LALIT S. PAWAR PROF.ABHIJEET DANDAVATE

GUIDE HEAD OF DEPARTMENT

DR.S.B.ALLAMPALLEWAR

EXTERNAL EXAMINER PRINCIPAL

 ACKNOWLEDGEMENT
It gives me an immense pleasure to express my sincere and heartiest gratitude towards
my guide Prof. Lalit S.Pawar for his guidance, encouragement, moral support and affection
through the course of my work. He has proven to be an excellent mentor and teacher. I am
especially appreciative to his willingness to listen and guide me to find the best solution,
regardless of challenge.
Of greatest importance, I am also extremely grateful to Prof. Abhijit Dandavate,
Head of Mechanical engineering Dept., for their motivation and support during the work
from time to time. I am also thankful to our P.G. Co-ordinator Prof. B.Anantharama for
their valuable guidance. I am also thankful to our principal Dr. S.B.Allampallewar for their
inspiration and his valuable suggestions.
This work is also the outcome of the blessing guidance and support of my parents and
family members. Lastly, my cordial thanks to all who have contributed intellectually and
materially in words and deeds for completion of this work.

Mr. Malwadkar Prashant B

 ABSTRACT

.
The present experimental work is carried out with copper and stainless steel Matrix
coil wire inserts 1mm wire diameter and of different density. Dense, medium, fine density 8,
10,12 no’s of wire matrix turns per 10 mm pitch. 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
Nusselt number for various Matrix coil wire inserts with varying density & different
materials. The Reynolds number is varied from 5000 to 13000. Correlations for Nusselt
number and friction factor are developed for the Matrix coil wire inserts from the obtained
results. The results of varying density with two materials have been compared with the values
for the smooth tube. The copper insert with high density (12 nos of wire matrix turns per 10
mm pitch) shows increase in Nusselt number values by 218% & in friction factor by 140% as
compared to the smooth tube values. The Stainless steel insert with high density (12 nos of
wire matrix turns per 10 mm pitch) is showing increase in Nusselt number values by 179%
and increase in friction factor by 140% as compared to the smooth tube values. When the
above two material inserts are compared then the copper is having enhancement 1.49 to 2.3
and for SS enhancement is 1.35 to 1.8 hence comparing all the inserts the copper is having
high heat transfer enhancement for same Reynolds number. The experimental results of heat
transfer in circular tube equipped with the different inserts is studied using a CFD program
and used to predict the output functions by designing a program. The inputs to the program is
Reynolds No, Temperatures and the output of the system is Nusselt number.

Keywords: Enhancement, heat transfer, Matrix coil wire inserts, density of matrix insert,,
pressure drop
 CONTENTS

Sr. No. Title Page No.

Title i

Certificate ii

Acknowledgement iii

Abstract iv

Contents v

List of Figures viii

List of Graphs x

List of tables xii

Nomenclature xiii

1. Introduction 1
1.1 Velocity Boundary Layer 2

1.2 Thermal Boundary Layer 3

1.3 Classification of Augmentation Techniques 4

1.4 Types of Artificial Roughness, Corrugated 8

or Wavy Channels

1.5 Organization of thesis 8

1.6 Objectives 9

2. Literature Review 10
 2.1 Performance Evaluation Criteria 10

2.2 Experimental work done on various inserts 12

2.3 Research Opportunities 19

3. Experimental Setup 20

3.1 Present Experimental work 20

3.2 Experimental Setup 21

3.3 Experimental Procedure 22

3.4 Experimental work carried out on inserts 23

3.5 Fabrication procedure 24

4. Methodology 27

4.1 Mathematical modeling 27

5 Experimental Results and Discussion 31

5.1 Results and Discussions of graphs of with & without

inserts at 80V 31

5.2 Graphs for validation 32

5.3 Graphs for the comparison of Nusselt No. (Nu (exp))

among without insert, with Copper and SS 33

5.4 Graphs for the comparison of Friction Factor among

without insert, with Copper and SS 35

5.5 Graphs for the comparison of heat transfer coefficient

(hexpt) among without insert, with Copper and SS 37

 5.6 Graphs for the comparison of heat transfer enhancement

(η) among without insert, with Copper and SS 38

6 CFD programming 41

6.1 CFD Analysis process 41

6.2 CFD Analysis steps 41

6.3 CFD post process of simulation to get results 43

6.4 Computational analysis in ANSYS-FLUENT 44

6.5 Model construction and mesh generation 44

6.6 CFD solver set up 46

6.7 CFD Results and discussions graphs using CFD analysis 50

7 Conclusion & Future Scope 52

7.1 Result discussion 52

7.2 Future Scope 53

8 References 54

APPENDIX-I 58

ANNEXTURE- I 63
 LIST OF FIGURES

Fig. No. Title of Figure Page No.

1.1 Velocity Boundary Layer 2

1.2 Growth of velocity and thermal boundary layer 3

1.3.1 Twisted tapes 4

1.3.2 Coiled wire inserts 5

1.3.3 Conical turbulators 6

1.3.4 Electrostatic experimental setup 6

1.3.5 Air impingement facility 7

3.1.1 Experimental set up for forced convection 20

3.1.2 Schematic diagram of forced convection set up 21

3.1.3 Schematic of Matrix coil wire insert 24

3.5.1(a) SS Matrix coil wire of high density 12 turns per pitch 25

3.5.1(b) SS Matrix coil wire of medium density 10 turns per pitch 25

3.5.1(c) SS Matrix coil wire of low density 8 turns per pitch 25

3.5.2(a) Cu Matrix coil wire of high density 12 turns per pitch 26

3.5.2(b) Cu Matrix coil wire of medium density 10 turns per pitch 26

3.5.2(c) Cu Matrix coil wire of low density 8 turns per pitch 26

6.5.1 CFD Modular geometry creation 45

6.5.2 CFD Geometry coil details 45
6.5.3 CFD Mesh 46
6.5.4 CFD Mesh details 46
6.7.1 Temp distibution on plain tube at V=7.18 m/s q=554.16 w/m2 47
 On tube surface
6.7.2 Contour of Nu no, on plain tube. Nu=35.12,V=7.18m/s 47
q=554.16 w/m2
6.7.3 Temp distibution on plain tube at V=3.99m/s q=485.3 w/m2 48
On tube surface
6.7.4 Contour of Nu no, on plain tube. Nu=22.08,V=3.99m/s 48
q=485.34 w/m2
6.7.5 Temp distribution on pipe surface after coil insertes at V=8,66 m/s
q= 704.96 w/m2 48
6.7.6 Temp distribution on coil at V=8.66 m/s,q=704.96 w/m2 49
6.7.7 Contour of Nu no, on plain tube. Nu=56.72,V=8.66m/s 49
q= 704.96 w/
 LIST OF GRAPHS

Graph No. Title of Graph Page

No.

5.2.1 Validation results for friction factor for plane tube 32

5.2.2 Validation results for friction factor for plane tube 32

5.3.1 Comparison of Nu for same pitch & varying density for Cu inserts 33

5.3.2 Comparison of Nu for same pitch & varying density for SS inserts 33

5.3.3 Comparison of Nu for all inserts 34

5.4.1 Friction factor comparison for same pitch & varying density for Cu inserts 35

5.4.2 Friction factor comparison for same pitch & varying density for SS inserts 35

5.4.3 Friction factor comparison for all inserts and without inserts 36

5.5.1 Heat transfer coeff. comparison for copper inserts 37

5.5.2 Heat transfer coeff.comparison for SS inserts 37

5.5.3 Heat transfer coefficient comparison for all inserts 38

5.6.1 Enhancement for copper inserts for same pitch & varying density 39

5.6.2 Enhancement for SS inserts for same pitch & varying density 39

5.6.3 Enhancement for all inserts 40

6.8.1 Comparison of Nu CFD for same pitch & varying density for SS inserts 49

6.8.2 Comparison of Nu CFD for same pitch & varying density for SS inserts 50
 LIST OF TABLES

Fig. No. Title of Table Page No.

2.1 Performance Evaluation Criteria for Single Phase Forced

Convection in enhanced Tubes of Same Envelope Diameter

(di) as the smooth Tube 11

3.1 Detailed specifications of Matrix coil wire inserts 24

4.1.1 Sample observation table 28

 NOMENCLATURE

A0 area of orifice, (m2)

A test section inner tube area, (π/4 D2 ) (m2)
Cp specific heat of air, (J/kg K)
Qa air discharge through test section (m3/sec)
D Inner diameter of test section, (m)
H pitch ,(mm)
w width of wavy tape insert,(mm)
H/D twist ratio
f th friction factor(theoretical) for plain tube
f friction factor(experimental) for plain tube
fi friction factor obtained using tape inserts
h experimental convective heat transfer coefficient, (W/m2K)
hw manometer level difference,(m)
hair equivalent height of air column, (m)
k thermal conductivity, (W/mK)
L length of test section, (m)
̇ mass flow rate of air, (Kg/sec)
Nui Nusselt number (experimental) with tape inserts, (hD/k)
Nu Nusselt number (experimental) for plain tube
Nuth Nusselt number for plain tube (theoretical)
Pr Prandtl number
p pitch, (m)
ΔP pressure drop across the test section, (Pa)
Q total heat transferred to air (W)
Re Reynolds number, (ρ V D/μ)
T1, T8 - air temperature at inlet and outlet, (°K)
T2, T3, T4, T5 - tube wall temperatures, (°K)
Ts average Surface temperature of the working fluid, (°K)
Tb bulk temperature, (°K)
V air velocity through test section, (m/sec)

Greek symbols
ν Kinematic viscosity of air, (m2/sec)
μ dynamic viscosity, (kg/m s)
η Over all enhancement
ρw density of water, (Kg/m3)
ρa density of air (Kg/m3)
 CHAPTER 1
INTRODUCTION
Heat exchangers are widely used in various industrial processes for heating and
cooling applications such as air conditioning and refrigeration systems, heat recovery
processes food and dairy processes, chemical process plants etc. The major challenge in
designing a heat exchanger is to make the equipment compact and achieve a high heat
transfer rate using minimum pumping power. Techniques for heat transfer augmentation are
relevant to several engineering applications. In recent years, the high cost of energy and
material has resulted in an increased effort aimed at producing more efficient heat exchange
equipment. Furthermore, sometimes there is a need for miniaturization of a heat exchanger in
specific applications, such as space application, through an augmentation of heat transfer. For
example, a heat exchanger for an ocean thermal energy conversion (OTEC) plant requires a
heat transfer surface area of the order of 10000 m2/MW . Therefore, an increase in the
efficiency of the heat exchanger through an augmentation technique may result in a
considerable saving in the material cost. Furthermore, as a heat exchanger becomes older, the
resistance to heat transfer increases owing to fouling or scaling. These problems are more
common for heat exchangers used in marine applications and in chemical industries. In some
specific applications, such as heat exchangers dealing with fluids of low thermal conductivity
(gases and oils) and desalination plants, there is a need to increase the heat transfer rate. The
heat transfer rate can be improved by introducing a disturbance in the fluid flow thereby
breaking the viscous and thermal boundary layer. However, in the process pumping power
may increase significantly and ultimately the pumping cost becomes high. Therefore, to
achieve a desired heat transfer rate in an existing heat exchanger at an economic pumping
power, several techniques have been proposed in recent years and are discussed under the
classification section.

1.1 Velocity Boundary layer:

Consider a flow of fluid over a flat plate held parallel to the direction of flow as
shown in Fig. 1.1. The velocity begins with value zero at the wall and increases within a thin
layer of thickness , to the value of free stream velocity u.
 Fig.1.1 Velocity Boundary Layer

From the fig 1.1 it can be observed that when the fluid travels further down-stream
along the plate, the retardation of fluid flow progresses due to viscous shear, and the
boundary layer grows in thickness. As a result the velocity gradient gradually decreases.
Meanwhile the boundary shear is reduced as the thickness increases. When the boundary
layer becomes thick enough, the particles begin to move out of smooth layers and the laminar
motion becomes unstable making the flow finally turbulent. However under the turbulent
boundary layer, there is still a thin layer of fluid immediately next to the solid boundary and
this is still flowing in the laminar pattern. This is called the laminar sub layer. The thermal
efficiency or performance evaluation criteria is an useful parameter which can be explained
as ratio of Nusselt number with friction factor of with and without insert which ultimately
proves that whether the insert is useful or not. The thermal efficiency of heat transferring
devices has been found to be generally 1.2 to 2.2 times less than the artificial enhancement
like twisted tape, coiled wires etc. due to their inherently low heat transfer capability between
any surface and air flowing on the surface. By providing artificial roughness or wavy
channels on the surface the heat transfer coefficient can be enhanced. However, the energy
for creating such turbulence has to come from the fan or blower. It is therefore; the
turbulence must be created only in the region very close to the heat transfer surface, i.e. in the
laminar sub-layer only. Therefore the experimentation should be carried out concentrating the
laminar sub layer only.

1.2 Thermal boundary layer:

Analogous to the concept of velocity boundary layer, there exists the development of
thermal boundary layer with temperature varying from Tw to T in the boundary layer
thickness t as shown in fig. 1.2.1.. A fluid at uniform temperature T flows along a flat plate
maintained at a constant temperature Tw. A dimensionless temperature  (x, y) as:
(Tw – T)
 (x, y) = (Tw –T•) . [1]

Where,
T (x, y) are the local temperatures in the fluid.
then at y = 0,  = 0;
y = ,  = 1.

Fig.1.2 Growth of velocity and thermal boundary layer

From the figure 1.2.1 it can be observed that, at each location along the plate there
exist a location y = t (x) in the fluid where  equals 0.99. The locus of such points where  =
0.99, is called thermal boundary layer t (x). The relative thickness of thermal boundary layer
t (x) and the velocity boundary layer (x) depend on the Prandtl number of the fluid.
Therefore, when the fluid comes in contact with the surface, the Prandtl number has to
reduce, as for low Prandtl number the fluid diffuses heat much faster than momentum flow.
For fluids having Pr<< 1, t >>the velocity boundary layer is fully contained within the
thermal boundary layer. Therefore when the experimentation will be carried out the results of
Prandtl number should be less than1 to get the performance evaluation greater than1.

1.3 Classification of Augmentation Techniques:

They are broadly classified into three different categories:
1. Passive Techniques
2. Active Techniques
3. Compound Techniques.
1) Passive Techniques: These techniques do not require any direct input of external power;
rather they use it from the system itself which ultimately leads to an increase in fluid pressure
drop. They generally use surface or geometrical modifications to the flow channel by
incorporating inserts or additional devices like twisted tapes, twisted wires, circular rings etc.
They promote higher heat transfer coefficients by disturbing or altering the existing flow
behavior except for extended surfaces. Heat transfer augmentation by these techniques can be
achieved by using ;
(i) Treated Surfaces: Such surfaces have a fine scale alteration to their finish or coating which
may be continuous or discontinuous. They are primarily used for boiling and condensing
duties. There are various treated surfaces available like coiled wire, twisted wire, spring wire
and one such type treated surface, twisted tape is shown below.

Fig. 1.3.1 Twisted tapes

(ii) Rough surfaces: These are the surface modifications that promote turbulence in the flow
field in the wall region, primarily in single phase flows, without increase in heat transfer
surface area.
(iii) Extended surfaces: They provide effective heat transfer enlargement. The newer
developments have led to modified finned surfaces that also tend to improve the heat transfer
coefficients by disturbing the flow field in addition to increasing the surface area.
(iv) Displaced enhancement devices: These are the inserts that are used primarily in confined
forced convection, and they improve energy transport indirectly at the heat exchange surface
by displacing the fluid from the heated or cooled surface of the duct with bulk fluid from the
core flow.
(v) Swirl flow devices: They produce and superimpose swirl flow or secondary recirculation
on the axial flow in a channel. These include helical strip or cored screw type tube inserts,
twisted tapes. They can be used for single phase and two-phase flows.
(vi) Coiled tubes: These lead to relatively more compact heat exchangers. It produces
secondary flows and vortices which promote higher heat transfer coefficients in single phase
flows as well as in most regions of boiling. As explained in treated surface another type of
insert named coiled wire is shown below.
 Fig 1.3.2 Coiled wire inserts

(vii) Surface tension devices: These consist of wicking or grooved surfaces, which direct and
improve the flow of liquid to boiling surfaces and from condensing surfaces.
(viii) Additives for liquids: These include the addition of solid particles, soluble trace
additives and gas bubbles in single phase flows and trace additives which usually depress the
surface tension of the liquid for boiling systems.
(ix) Additives for gases: These include liquid droplets or solid particles, which are introduced
in single-phase gas flows either as dilute phase (gas-solid suspensions)or as dense phase
(fluidized beds).
2) Active Techniques: In these cases, external power is used to facilitate the desired flow
modification and the relative improvement in the rate of heat transfer. Augmentation of heat
transfer by this method can be achieved by
(i) Mechanical Aids: Such instruments stir the fluid by mechanical means or by rotating the
surface. These include rotating tube heat exchangers and scrapped surface heat and mass
exchangers.
(ii) Surface vibration: They have been applied in single phase flows to obtain higher heat
transfer coefficients.
(iii) Turbulators: These are primarily used in single phase flows and are considered to be
perhaps the most practical type of vibration enhancement technique. The turbulators comes
under active technique and hence require external power for heat enhancement. The conical
turbulators shown below gives the vibratory action to the fluid particles and hence create
turbulence.

Fig. 1.3.3 Conical turbulators

(iv) Electrostatic fields: It can be in the form of electric or magnetic fields or a combination
of the two from dc or ac sources, which can be applied in heat exchange systems involving
dielectric fluids. Depending on the application, it can also produce greater bulk mixing and
induce forced convection or electromagnetic pumping to enhance heat transfer. The figure
1.3.4 shows that the boiling process takes place on a horizontally–oriented, circular surface,
which is actually the top surface of a cylindrical copper block. The sides of the copper block
are insulated with Teflon and heat is supplied by two 400 W electric cartridges which hallow
for heat fluxes of up to 115 W/cm2. A water-cooled condenser, which is set at a tilt angle of
20° above the horizontal plane, is used to condense the vapor generated at the boiling surface
back to the pool so that the pressure in the vessel can be controlled. The condensate is
introduced through the bottom of the vessel in order to avoid any disturbance caused by
liquid falling directly on the liquid–vapor interface. A coil heater wound around the glass
vessel keeps the working fluid at a fixed temperature and makes up for any heat losses. It was
observed that the natural convection–nucleate boiling transition is more pronounced for R-
113 than that for n-pentane and R-123.

Fig. 1.3.4 Electrostatic experimental setup

(v) Injection: Such a technique is used in single phase flow and pertains to the method of
injecting the same or a different fluid into the main bulk fluid either through a porous heat
transfer interface or upstream of the heat transfer section.
(vi) Suction: It involves either vapor removal through a porous heated surface in nucleate or
film boiling, or fluid withdrawal through a porous heated surface in single-phase flow.
(vii) Jet impingement: It involves the direction of heating or cooling fluid perpendicularly or
obliquely to the heat transfer surface. In the figure shown below air at ambient conditions is
drawn into a variable-speed regenerative blower. The air flow rate is measured by one of
three flow meters depending on the range, and delivered to a cylindrical plenum for flow
conditioning. Different plates containing orifices can be attached to the underside of the
plenum. A pressure tap located on the plenum wall is used to measure pressure drop across
the orifice, while a thermocouple measures the air temperature just upstream of the orifice.
The jet issuing from the orifice plate impinges on a target plate which contains the heat
source assembly.

Fig. 1.3.5 Air impingement facility

3) Compound Techniques: When any two or more of these techniques are employed
simultaneously to obtain enhancement in heat transfer that is greater than that produced by
either of them when used individually, is termed as compound enhancement. This technique
involves complex design and hence has limited applications.

1.4 Types of artificial roughness, corrugated or wavy channels:

The roughness elements are classified as follows:

a) According to arrangement of ribs: Depending on whether one complete rib or ribs in

pieces are placed on absorber plate, the ribs can be full (continuous) or broken (discrete).

b) According to orientation of ribs: transverse, inclined and V- shaped.

c) According to shape of cross section of ribs: square, rectangular, circular, semi-Circular,

trapezoidal, triangular.

d) According to material of ribs: Aluminium, copper, brass etc.

e) According to geometry: Sand grains, ribs, dimples, expanded metal wire mesh,
Compound rib groove arrangement Corrugated or wavy channels.
f) According to method of attachment of ribs: Gluing, casting, machining of roughness
elements on heat transfer surface.

1.5 Organization of thesis:

1. Deals with the literature review that has been done with the various techniques used
for enhancement. It gives in detail the observations that were made using passive
techniques.
2. Includes the present experimental work which was done with a new kind of insert
called Matrix coil wire inserts. It also includes the fabrication of the same.
3. Deals with the results and discussion about the work done with the inserts. A
Comparison of friction factor, heat transfer coefficients, Nusselt number theoretical &
experimental, made with the smooth tube, for Stainless steel & Cu.

1.6 Objectives:
1. To investigate the effect of various density of wire matrix inserts of copper and
stainless steel inserts on heat transfer rate.
2. To correlate theoretical and experimental results of parameters like heat transfer
coefficient, Nusselt number, Friction factor between Copper and stainless steel..
3. To find out the optimum result with pressure drop.
4. To develop an experimental facility for studying turbulent flow heat transfer and fluid
friction in a test pipe with Matrix coil wire inserts.
5. To analyze the heat transfer performance.
6. To compare the results obtained from both cases (Test pipe with and without inserts).
7. To choose the material between Copper and Aluminium depending on the material
properties like thermal conductivity, density along with the properties like heat
transfer rate and pressure drop.
8. To compare the results of Matrix coil wire inserts with plane tube insert to observe
increment or decrement in parameters like Nusselt number, friction factor,
enhancement ratio.

Chapter 2 deals with the literature review that has been done with the various techniques used
for enhancement. It gives in detail the observations that were made using passive techniques.
Chapter 3 includes the present experimental work which was done with a new kind of insert
called Matrix coil wire inserts. It also includes the fabrication procedure .

Chapter 4 deals with the results and discussion about the work done with the inserts. A
comparison of friction factor and heat transfer coefficient is made with the smooth tube.
 CHAPTER 2
LITERATURE REVIEW

The heat transfer duty or thermal performance of heat exchangers can be improved by
heat transfer enhancement techniques. There are lot of investigations carried out on the shape,
size, and orientation, etc. of the various inserts and rough surfaces like coiled wire, twisted
bar, helical screw etc. Several investigators have attempted to design a roughness element,
corrugated or wavy channels, which can enhance convective heat transfer with minimum
increase in friction losses. The various papers are reviewed below in literature review to
identify any better scope for the heat transfer enhancement using passive techniques. A
significant number of papers are reviewed which relate to the science of heat transfer,
comprising experimental, numerical and analytical studies. Others relate to applications
where heat transfer plays a major role, not only in man-made devices but in natural systems
as well. The papers are grouped into subject-related categories and then into subfields within
these categories.

2.1 Performance Evaluation Criteria:

In many practical applications of enhancement techniques, the following
performance objectives, along with a set of operating constraints and conditions, are usually
considered for evaluating the thermo-hydraulic performance of a heat exchanger:
• Increase in the heat duty of an existing heat exchanger without altering the pumping power
or flow rate requirements.
• Reduction in the approach temperature difference between the two heat exchanging fluid
streams for a specified heat load and size of exchanger.
• Reduction in the size or heat transfer surface area requirements for a specified heat duty and
pressure drop.
• Reduction in the process stream’s pumping power requirements for a given heat load and
exchanger surface area.

Table 2.1 PEC for Single Phase Forced Convection in enhanced Tubes of Same
Envelope Diameter (di) as the smooth Tube
 FIXED

Case Geometry m P Q ∆Ti Objective

FG-1a NL X X Q↑

FG-1b NL X X ∆Ti↓

FG-2a NL X X Q↑

FG-2b NL X X ∆Ti↓

FG-3 NL X X P↓

FN-1 N X X X L↓

FN-2 N X X X L↓

FN-3 N X X X P↓

VG-1 ---- X X X X (NL)a↓

VG-2a (NL)a X X X Q↑

VG-2b (NL)a X X X ∆Ti↓

VG-3 (NL)a X X X P↓

Different criteria used for evaluating the performance of a single phase flow are as follows:
1) Fixed Geometry (FG) Criteria: The area of flow cross-section (N and di) and tube length
L are kept constant. They would typically be applicable for retrofitting the smooth tubes
of an existing exchanger with enhanced tubes, thereby maintaining the same basic
geometry and size (N, di, L). This is well explained in the table 2.1 for the case of fixed
geometry from FG-1a to FG-3, where the objectives can be achieved by changing the
desired parameters.The objectives then could be to increase the heat load Q for the same
approach temperature ∆Ti and mass flow rate m or pumping power P, or decrease ∆Ti or
P for fixed Q and m or P; or reduce P for fixed Q.
2) Fixed Number (FN) Criteria: The flow frontal area or cross-section (N and di) is kept
constant and the heat exchanger length is allowed to vary. Here the objectives are to
 reduce either the heat transfer surface area (A→ L) or the pumping power P for a fixed
heat load. These objectives are explained in the table 2.1 using three cases from FN-1 to
FN-3.
3) Variable Geometry (VG) Criteria: The number of tubes and their length (N & L) are kept
constant, but their diameter can change. A heat exchanger is often sized to meet a
specified heat duty Q for a fixed process fluid flow rate m. Because the tube side velocity
reduces in such cases so as to accommodate the higher frictional losses in the enhanced
surface tubes, it becomes necessary to increase the flow area to maintain constant m. This
is usually accomplished by using a greater number of parallel flow circuits.

After referring the table 2.1 the experimentation can be done by using any criteria
mentioned above but if there exist any modifications in the heat exchangers and if large heat
exchangers are considered then it would be difficult to change the length and diameter of the
test pipe hence it would be beneficial to go for Fixed Geometry (FG) criteria. Therefore the
present study is carried out by considering FG-2b where the heat is supplied at constant heat
load and at constant pumping power.

2.2 Experimental work done on various inserts

From the above study the experimental work is carried out on the basis of fixed
geometry. As per the requirement of our experiment, the study is categorized into boundary
layers and external flows, change of phase and channel flows, which are explained in detail in
succeeding sections.

A] Boundary layers and external flows:

Study on boundary layers and external flows have been categorized as flows
influenced externally, flows with special geometric effects, compressible and high-speed
flows, analysis and modeling techniques, unsteady flow effects, flows with film and
interfacial effects and flows with special fluid types or property effects. External effects on
boundary layers including swirl, oscillation, and unsteadiness imposed by forcing the flow,
elevated external turbulence levels are included in literature below. Many papers deal with
variations in geometry. Such geometric features include surface roughness elements,
embedded micro channels or grooves, porous heat transfer walls(with suction or injection);
baffles, solid and porous, vortex generators, turbulators, twisted tape, corrugations, fins of
various shapes, cylinders of various shapes, spheres, rod bundles and rod bundle support
structures are included in literature below.
Hsieh and Huang [1] conducted experimental studies for heat transfer and pressure
drop of laminar flow in horizontal tubes with/without longitudinal inserts. They reported that
enhancement of heat transfer as compared to a conventional bare tube at the same Reynolds
number to be a factor of 16 at Re >10000, while a friction factor rise of only 4.5. A new
method was postulated by Sarma[2] to predict heat transfer coefficients with twisted tape
inserts in a tube in which the wall shear and the temperature gradients were properly
modified through friction coefficient correlation leading to heat transfer augmentation from
the tube wall. It was found that the performance evaluation criteria was about 1.32–1.39
times compared to plain tube. Experimental studies on heat transfer and flow characteristics
for turbulent flow of air in a horizontal circular tube with strip type insert (longitudinal and
Crossed Strip inserts). Hsieh[3] reported that friction factor rise due to inclusion of inserts
was typically between 1.1 and 1.5 from low Re (=27000) to high Re (=55500) with respect to
bare tube. Experimental investigations for the heat transfer characteristics and the pressure
drop in horizontal double pipes with twisted tape inserts were carried out by Naphon [4].
Heat transfer, friction factor and enhancement efficiency characteristics in a circular tube
fitted with conical ring turbulators and a twisted-tape swirl generator were investigated
experimentally by Promvonge and Eiamsaard [5]. Ozceyhan and Siebel Gunes [6] conducted
experimental investigations of heat transfer and pressure drop in a tube with coiled wire
inserts placed separately from the tube wall and they found the enhancement ratio of about
1.5 as compared to the plain tube. Dasmahapatra and Rao [7] studied augmentation of heat
transfer to viscous non-Newtonian fluids in laminar flow using full width interrupted twisted
tapes under the uniform wall temperature condition. Al-Fahed and Chakroun [8] investigated
the effect of tube-tape clearance on heat transfer under fully developed turbulent flow
conditions in a horizontal isothermal tube. Investigations were carried out on twisted tape
inserts in viscous flow in a horizontal tube by Manglik and Bergles [9]. Experimental data
were obtained for water and ehtylene glycol with snug-fit tape inserts of three different twist
ratios, y=3.0, 4.5, and 6.0; the tape thickness in each case was 0.483 mm. In continuation of
their research, an extended review of the application of twisted-tape inserts in tubular heat
exchangers and their thermal-hydraulic performance was discussed by Manglik and
Bergles[10]. Twisted tapes promote enhanced heat transfer by generating swirl or secondary
flows, increasing the flow velocity due to the tube partitioning and blockage. Experiments
were conducted on compound heat transfer enhancement in a tube fitted with serrated twisted
tape in the Reynolds number range of 10000 to 57000 by Chang[11]. Heat transfer and
pressure drop characteristics of laminar flow in rectangular and square plain ducts and ducts
with twisted-tape inserts were experimentally investigated by Saha and Mallick[12].
Experimental investigation of heat transfer and friction factor characteristics of circular tube
fitted with full-length helical screw element of different twist ratio, and increasing and
decreasing order of twist ratio set have been studied with uniform heat flux by
Sivashanmugam and Suresh[13]. Ozceyhan and Siebel Gunes [14] conducted experiments
with equilateral triangle cross sectioned coiled wire inserts and they found the maximum
performance evaluation of about 1.38 as compared to the plain tube. They performed their
experiments for various Reynolds numbers and the obtained experimental data were then
compared with those previously reported in the literature. They reported higher performance
of the helical twisted insert in comparison with the twisted tape insert. Modification of
twisted tape was made by focusing on the increase of heat transfer rate rather than the
reduction of friction loss by Rahimi [15]. The tapes in this group were designed to offer
stronger swirl flow and better mixing than the typical one. However, the enhanced heat
transfer by the use of the twisted tapes in the group was certainly accompanied by the rise of
friction factor. In general, the performance factors of twisted tapes in this group were higher.
Heat transfer and pressure drop characteristics in a circular tube fitted with and without V-cut
twisted tape insert were studied by P. Murugesan, P.S.S. Srinivasan[16] for different twist
ratios & width ratios & observed that Nusselt number & friction factor increases with
decrease in twist ratio & width ratio.

B. Change of phase—boiling and evaporation

Study on boiling change of phase have been explained as follows Those that focus on
droplet and film evaporation, bubble characteristics, pool boiling, film boiling, flow or forced
convection boiling, and two-phase thermo-hydrodynamic effects. Some discuss surface
geometry effects, such as micro porous coatings, micro fins, or tube inserts. Some deal with
interface characteristics, such as contact angle.
Experimental studies were carried out on the heat transfer enhancement and pressure drop
characteristics in presence of twisted tape inserts, during flow boiling of R-134a inside a
horizontal evaporator for plain flow and four tubes with twisted tapes of 10, 14, and 18 twist
ratios and four refrigerant mass velocities of 54, 85, 114 and 136 kg/s m2 for each tape. It has
been found that the twisted tape inserts enhance the heat transfer coefficient on relatively
higher pressure drop penalty, in comparison to that for the plain tube flow by Kumar [17].
Experimental studies for tubes fitted with left - right twisted tape inserts of various twist
ratios to enhance the convective heat transfer rates for thermo siphon solar water heater
system by Jaisankar [18]. Experimental investigations were carried out on the heat transfer
enhancement and pressure drop characteristics in the presence of twisted tape inserts, during
flow boiling of R-134a, inside a horizontal evaporator by Akhavan-Behabadi [19]. An
increase in heat transfer coefficient by 12% and increase in friction factor by 15% for tape
with trapezoidal-cut was observed as compared to the plain tube. Experimental investigation
on heat transfer and friction factor characteristics of circular tube fitted with right-left helical
screw inserts of equal length, and unequal length of different twist ratio have been presented
by Sivashanmugam and Nagarajan[20]. The short-length tape is introduced as a swirling flow
device for generating a strong swirl flow at the tube entry while the full-length twisted tape is
inserted into the tested tube at a single twist ratio of pitch/width (y/w) =4.0. The enhancement
efficiency of the tube with the short-length tape insert is found to be lower by 5% than that
with the full-length one. In continuation, investigations were carried out in a tube equipped
with the combined devices between the twisted tape (TT) and constant/ periodically varying
wire coil pitch ratio by Eiamsard. The highest thermal performance factor of around 1.25 is
found by using DI-coil in common with the TT at lower Reynolds number. Also experiments
were performed using single twisted tapes and full-length dual twisted tapes with three
different twist ratios (y/w=3.0, 4.0 and 5.0) and also regularly-spaced dual twisted tapes with
three different space ratios (S/D=0.75, 1.5 and 2.25). The effects of major parameters on heat
transfer and friction factor are discussed. The result shows that the heat transfer of the tube
with dual twisted tapes is higher than that of the plain tube with/without single twisted tape
insert by Eiamsard [21]. Heat transfer, flow friction and thermal performance factor
characteristics in a tube fitted with delta-winglet twisted tape, using water as working fluid
are investigated experimentally for oblique delta-winglet twisted tape (O-DWT) and straight
delta-winglet twisted tape (S-DWT) arrangements over a Reynolds number range of 10000–
57,000 by considering three twist ratios (y/w = 3, 4 and 5) and three depth of wing cut ratios
(DR = d/w = 0.11, 0.21 and 0.32) by Wongcharee. The results show that Nusselt number and
mean friction factor in the tube with the delta-winglet twisted tape increase with decreasing
twisted ratio (y/w) and increasing depth of wing cut ratio. Patil[22] studied the frictional and
heat transfer characteristics of laminar swirl flow of pseudo plastic type power law fluid in a
circular tube using varying width twisted tapes under a uniform wall temperature condition.
Reduced width twisted tape inserts gave 18%–56% lower isothermal friction factors than the
full width tapes. Nusselt numbers decreased only slightly by 5% and 25%, for tape widths of
19.7 and 11.0 mm, respectively inside a 28mm diameter tube. Also, the reduced width tapes
offered 20% – 50% savings in the tape material as compared to the full width tapes, which is
more economical. The present investigation is aimed at studying the frictional and heat
transfer characteristics in turbulent region using varying width twisted tape inserts under
constant wall heat flux. The objective of using varying (reduced) width twisted tapes is to
reduce the pressure drops associated with full width twisted tapes without seriously impairing
the heat transfer augmentation rates and to achieve material savings. Wang and Sunden [23]
introduced a comparison of the thermal and hydraulic performances between twisted tape and
coiled wire inserts for both laminar and turbulent flow regimes. They reported that coiled
wire inserts provided better overall enhancement than the twisted tape inserts. The thermal
augmentation in circular tube with twisted tape and wire coil inserts was experimentally
investigated by Promvonge[24]. The results indicated that the existence of wire coils together
with twisted tapes yielded more heat transfer over the use of wire coil/twisted tape alone. The
effect of the wire coils having different pitches on the thermal stress and conjugate heat
transfer under uniform heat flux was investigated by Ozceyhan [25]. It was found that the
maximum thermal stress ratio occurred in the case of p = 2d for 3 m/s mean water velocity.
The effect of different coiled wire geometry on pressure drop during condensation of R-134 a
vapor inside a horizontal tube was experimentally investigated by Akhavan-Behabadi [26].
Finally, they developed a new correlation based on the experimental data for predicting the
pressure loss in coiled wire inserted tubes. The correlation is given as follows
ρl .5 ρl .5
.9
.66 ρm in + ρm o t
Nu = 0.81Pr 3 Re 2
( X D/L )0.29 [2]

Where,
Nu = average Nusselt number = h D/k
Pr = liquid Prandtl number = mCp/k
Re = liquid Reynolds number = GD/m
G = liquid mass velocity considering total refrigerant is owing inside the tube as liquid
m,Cp,k = absolute viscosity, specific heat and thermal conductivity of liquid refrigerant
calculated at the saturation temperature corresponding to the average pressure existing in the
test section length
DX/L= change in vapour quality inside the test section per unit of its length.
 In another experimental study, Agrawal[27] experimentally studied the heat transfer
enhancement by using coiled wire inserts during forced convection condensation of R-22
inside a horizontal tube.

C. Channel flows:
Heat transfer in channels continues to see considerable attention in the literature both
through experimental and computational studies. The largest growth in study from previous
years was in the area of micro channel heat transfer. The review of articles was
subcategorized into the following areas such as straight-wall channels and ducts, ducts having
fins or profiling for heat transfer enhancement, flow and heat transfer in channels in complex
geometries, unsteady and transient flow and heat transfer in channels, micro channel heat
transfer, and channel flows with multi-phase and non-Newtonian flow. The straight-walled
duct provides a convenient environment to validate numerical schemes and explore the role
of boundary and initial conditions on fluid flow and heat transfer. The geometrical
possibilities for enhancing heat transfer using profiling, fins, protuberances, and the like, are
usually offset by the challenges of reducing system pressure loss by their addition. The
literature considered a rather comprehensive array of heat transfer augmentation strategies
including inner corrugations, rib-roughened tubes, slits and solid ribs, coiled and spiraled
inserts, pin fins, dimpling, v-shaped broken ribs, traverse-rib roughness, and various
strategies of simulating disturbances using jet ejection. Many studies included the issues of
pressure loss, both computational and experimental work was presented covering fully
laminar to turbulent flow conditions. Many practical heat transfer internal single-phase flow
problems are generally conducted in complex geometries. Geometries considered in the
literature included helical square ducts, concentric annuli, polygonal pipes, inclined elliptic
pipes, twisted ducts of various geometries, and geometries where one or more walls are
undulating. Other complex configurations that were studied involved flow in a packed bed, in
an air gap and seals of electric motors, and in fuel cell geometries. H. Gul, D.Evin [28]
experimentally studied the heat transfer enhancement in circular tubes using helical swirl
generator insert at the entrance. It was shown that the coil wire inserts increased both heat
transfer and friction factor in the tube. It was proved the enhancement efficiency of about 1.2
as compared to plain tube. Pongjet [29] experimentally studied the Thermal performance in
circular tube fitted with coiled square wires in which he proved that the average enhancement
efficiencies of the 3 mm square and circular ones are about 1.18 and 1.1, respectively.
Naphon [30] also made experiments by using conventional twisted tape inserts in horizontal
double pipe. The literature survey on investigations of twisted tape inserts shows that these
inserts are generally attached onto the tube walls in order to improve the heat transfer by not
only disturbing the laminar sub layer but also increasing the effective heat transfer area. In
this experimental study, unlike the studies available in the literature, the wavy twisted tape
inserts with different twist ratios(y/D) & different wave-widths were placed inside the tube
separated from the tube wall, thus the effective heat transfer area was increased and heat
transfer enhancement was achieved by disturbing the laminar sublayer. Moreover, it is known
that attaching the inserts onto the tube wall may cause contamination over time, so there will
occur an additional resistance to heat transfer. So there will be an additional resistance to heat
transfer [31, 32]. Thus, placing the inserts separated from the tube wall also provides
abatement of contamination.

2.3 Research Opportunities

The aim of insert is to enhance heat transfer rate by reducing the size and cost of heat
exchanger but not with the increase in pumping power. By referring the above literature it
was observed that the objective can be achieved if one goes for passive techniques. After
referring the results obtained from the Matrix coil wire inserts, they are offering less pressure
drop than the other techniques mentioned in above literature. There exists a lot of work on
coil wire inserts by various researchers by varying various pitches by diameter ratios or by
varying thickness to pitch ratio. The inserts can be modified by giving new design as it can be
made Matrix shape as if a material becomes corrugated the turbulence may rise in the fluid
flow. The extensive contact surface enhances the internal heat exchange between the phases
and consequently results in an increased thermal diffusivity. A coil wire inserts is a swirl
producing geometry where the secondary fluid motion is generated by the continuous change
in direction of the tangential vector to the bounding curve surface of the duct, which results in
the local deflection of the bulk flow velocity vector. The dense structure of the coil wire
insert causes increased turbulence giving improved heat transfer rates. Therefore a coil wire
inserts insert may prove to be beneficial by improving the heat transfer rate and by reducing
the pressure drop.
 CHAPTER 3
EXPERIMENTAL INVESTIGATION OF HEAT TRANSFER
PERFORMANCE OF MATRIX COIL WIRE INSERTS
3.1 Present experimental work
The experimental study on passive heat transfer augmentation using Matrix coil wire inserts
for varying density with stainless steel and copper as a material were carried on in a single
phase flow heat exchanger having the specifications as listed below:-

Fig.3.1.1 Experimental set up for forced convection

Specifications of set up:

1 Inner diameter of pipe = (do) = 0.026 m.
2 Outer diameter of pipe = (di) = 0.03 m.
3 Length of test section = L = 0.7m.
4 Capacity of blower = 0.5 h.p.
5 Diameter of orifice (d) =0.016m.
6 Range of Dimmerstat = 0 to 2 amp. 0-270V ac.
7 Temperature indicator = 0 to 300 0C. (12 points)
8 U-tube manometer = Pressure tappings at start and end of the test pipe. 0-300 mm of
water column
 9 Calibrated chromel alumel thermocouple(K-type- -2700C to 1350 0C)
10 Voltmeter = 0-200 V; ammeter 0-2 amp.
11 Nichrome wire (resistivity = 1.5 x 10-6 Ωm) heater wound around test pipe.

3.2 Experimental Set up

The apparatus consist of a blower unit fitted with the test pipe. The test section is
surrounded by nichrome heater. Six thermocouples are embedded on test section and two
thermocouples are placed in the air stream at the entrance and exit of test section to measure
air temperatures. Test pipe is connected to the delivery side of the blower along with the
orifice to measure flow of air through the pipe. Input to the heater is given through power unit
and is measured by meters. It is also noted that only a part of the total heat supplied is utilized
in heating the air. A temperature indicator with clod junction compensation is provided to
measure the temperature in the pipe wall in the test section. Air flow is measured with the
help of an orifice meter and the water manometer fitted on the board. In addition to this, an
inclined manometer is also used to measure pressure drop across test section. The valve at the
outlet of pipe is used to vary the flow rate of air. At inlet of test section a tapping with valve
is provided to measure pressure drop.

Fig 3.1.2 Schematic diagram of forced convection set up

T1 measures inlet air temp & is indicated by Digital Voltmeter (DV) on the front
panel. The thermocouple no 8 is used for measuring outlet air temperature. The
thermocouples T2 to T7 are used to measure surface temperature of test section. The power
control unit uses an isolating transformer for stepping down mains voltage to 130 volts AC &
get controlled DC output in the range 0-150 volts using uni junction transistor(UJT), pulse
transformer &Silicon Controlled Rectifier (SCR) circuit & capacitive filter. The heater power
is necessarily DC. The voltage signal (V) for measurement is obtained by means of a
potential divider & current signal (I) is obtained by measuring the voltage drop across a small
resistance. This current is measured by means of an ammeter on the front panel & for voltage
measurement test points are provided below the ammeter. The output can be controlled by
means of potentiometer. The ground is internally connected.

3.3 Experimental procedure

1. Refer to the Fig 3.1.2 and make all the cable connection carefully
2. Switch ON the unit.
3. Use power control button on the panel to get voltage at around 8ovolts & current at
around 0.455 amps. This will start the heating process.
4. Now blower should be started with valve opening at 100% level.
5. The temperatures will keep on rising continuously. When steady state is reached, note
all the temperatures for the smooth tube.
6. Now open the connection of the blower outlet and pipe through the flange provided at
the interface.
7. Now put the inserts of stainless steel and copper one by one inside the test pipe and
again make the connections between the blower and the test pipe.
8. The temperatures will keep on rising continuously. When steady state is reached,
acquire the data and observe all the results.
9. At steady state note down height differences across two limbs of water U-tube
manometer which corresponds to flow rate, also note the rise of liquid in inclined
manometer corresponding to pressure drop.
10. Repeat the steps from (2) to (9) for different power levels and different valve
positions.

3.4 Experimental work carried out on inserts:

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 researchers have used Matrix coil wire inserts with varying density where they
are getting higher friction factor of about 30% to 50 % hence an attempt have to be made to
reduce this friction factor. This attempt can be done by changing the shape of insert and also
by using various materials. The inserts used for the experiment are Matrix coil wire with
different densities with same pitch as there is no work done on such type of insert.
The work includes the following:
1. Determination of friction factor and Nusselt number for smooth tube and for various
Matrix coil wire inserts with varying densities.
2. The results of Nusselt number, friction factor, Performance evaluation criteria for all
the Stainless steel Matrix coil inserts are plotted on the graph and compared with the
values for the smooth tube.
3. Similarly all the above parameters for copper Matrix coil inserts are plotted on the
graph and compared with the values for the smooth tube.
4. Two materials are chosen for the experiment hence to find an optimum value in terms
of the above mentioned parameters ,combined graphs are plotted for copper &
stainless steel to find an optimum out of the two materials that can be used for this
experimental set up.
5. Comparing results of Matrix coil wire with plane tube

Fig 3.1.3 Schematic of Matrix coil wire Inserted

Specifications of Inserts :
i. Insert OD = 25mm.
ii. Pitch = 10mm,
iii. Density = 8,10,12 matrix coil wire per pitch
iv. Length of insert, L = 700 mm
v. Coil Wire diameter of inserts, d = 1mm
 Table 3.1: Detailed specifications of wavy twisted inserts
Sr. Density OD
Material Description
no. (No. of coils per pitch) (mm)
1 8 24 Stainless Steel
Same material with varying
2 10 24 Stainless Steel
density
3 12 24 Stainless Steel
4 8 24 Cu
Same pitch with varying
5 10 24 Cu
density
6 12 24 Cu

3.5 Fabrication Procedure

1. Take Stainless steel or copper sheet of 1mm diameter coil.

2. wind them on Special purpose winding machine in desired density and O.D. of insert
3. The insert is then cut to desired length.
The actual photographs of Stainless steel Matrix coil wire inserts for varying density but
same pitch are shown below from Fig.3.5.1 (a) to (c).

Fig.3.5.1(a) SS Matrix coil wire insert of high density 12 no of turns per pitch

Fig.3.5.1.(b) SS Matrix coil wire insert of medium density 10 no of turns per pitch
 Fig.3.5.1 (c)SS Matrix coil wire insert of low density 8 no of turns per pitch

In following figures 3.5.2 (a) & (b) the actual view of copper inserts used during experiment
are shown.

Fig.3.5.2(a) Copper Matrix coil wire insert of high density 12 no of turns per pitch

Fig.3.5.2.(b) Matrix coil wire insert of medium density 10 no of turns per pitch

Fig.3.5.2 (c) Copper Matrix coil wire insert of low density 8 no of turns per pitch
 CHAPTER 4
METHODOLOGY
4.1. Mathematical modeling carried out on insert

The heat flux applied to the test tube cause an increase in the outer surface
temperature Tout of the test tube in axial direction. Therefore, the heat loss is calculated for
each part of the test tube in which the thermocouples exist. The heat loss qloss is the heat
which get transfers from the outer tube wall to the surroundings.
qair = qconv (3)
qair = m Cpair (To-Ti) = ΔVI-qloss (4)
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.
The heat provided by the electrical cable in the test tube is only about 3 to 4% higher than the
heat absorbed by the air for the thermal equilibrium test because of the convection and
radiation heat losses (Qloss) from the test section to the surroundings. Therefore, only the heat
transfer rate absorbed by the air is taken into consideration for the convective heat transfer
coefficient calculation.
qai
q= (5)
π Do L
The procedure for calculating the various parameters for with and without inserts is
given below. The experimentation was done at constant heat supply of 87V; hence the
calculations are done at constant heat supply. A sample observation table is shown below to
understand the parameters need to be observed during experimentation.

Table 4.1.1 Sample observation table

Sr Manometer Inclined Manometer

Temperatures oC
No. Difference Reading
T1 T2 T3 T4 T5 T6 T7 T8 hw hf

where,
 T2 to T7 are the surface temperatures
T1 and T8 are the ambient temperature at inlet and outlet temperature of air.
hw is U-tube manometer difference in mm.
hf is reading on inclined manometer
Avg. Surface Temp., Ts= (T2+T3+T4+T5+T6+T7)/6 (6)

Avg. Temp of air, Tb= (T1+T8)/2 (7)

From table of properties of air the parameters like density of air (ρa), Kinematic viscosity (ν),
thermal conductivity (k), specific heat of air (Cp) ,Prandtl number (Pr) at 1atm pressure.

Manometer difference = water head = hw

ρ
Air head, ha=hw∗ (8)
ρ

where,
ρw = Density of water = 1000 kg/m3

Air volume flow rate, Qa = Cd *Ao ∗ ∗ℎ (9)

where,
A0= cross sectional area of orifice.
Mass flow rate, ̇ = Qa*ρa (10)

Velocity of air, V= Qa /A (11)

where,
A= cross sectional area of pipe.
Heat carried out, q = ̇ *Cp*(T8-T1) (12)

h= ( – )
(13)

where,
h = heat transfer coefficient.

Ts = surface temperature

The Reynolds number for the fluid is defined by,

VD
Re = (14)
υ
where,
V= velocity of the fluid.
ν = Kinematic viscosity of the fluid.
For internal flows if Reynolds (Re) number exceeds by 4000 then the flow is turbulent. After
the flow is decided i.e. laminar or turbulent then the Nusselt number can be calculated. The
theoretical Nusselt 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 (15)

This equation is called Dittus-Boettier equation.

fs = (1.82 log10Re-1.64)-2 (16)

This equation is used to find friction factor called as Petukhov equation for smooth surface.
where,
fs= Friction factor for smooth tube .
Re= Reynolds number.
The actual pressure drop & friction factor is calculated with the help of tappings at
both the ends of test pipe connected to U-tube manometer and the friction factor is calculated
from the formula given below:

Δ
f= (17)
∗

where,
Δ P= pressure difference at both ends of test pipe.
L= length of test pipe.
D= Inner diameter of pipe.

The experimental Nusselt number are calculated as given below:

Nu = hD/k (18)

Nu= Nusselt number

h = heat transfer coefficient

k = thermal conductivity of fluid

D = diameter of test section

The overall enhancement efficiency is expressed as the ratio of the Nusselt number of an
enhanced tube with wavy twisted tape insert to that of a smooth tube, at a constant pumping
power is introduced by Webb[19].
h⁄ /
PEC= η = (f h|f / ) /3
(19)

As per the methodology discussed above the experimental calculations are to be carried out
and the sample observation tables for with and without inserts are shown in the next section.
 CHAPTER 5

EXPERIMENTLE RESULTS & DISCUSSIONS

5.1 Results and Discussions of graphs of with and without inserts at 80V.

The parameters mentioned in the above objectives are achieved by carrying out
the experimentation and then making the comparisons of them for varying density and
material in the graphs drawn below.

The Nusselt number, friction factor are the important parameters which decides
the success of any experimentation work as both parameters are opposite to each other. The
Nusselt number shows the percentage increase in heat transfer enhancement when inserts are
placed inside a test pipe due to increase in heat transfer coefficient by comparing it, without
inserts. Contradictory to it is when inserts are placed inside the test pipe the friction gets
produced inside the test pipe due to which there is drop in pressure hence the desire increase
in heat transfer coefficient is offset by pressure drop. Hence, the inserts should be designed in
such a way that there pumping cost should get offset by heat enhancement.

The Nusselt number and the friction factor are obtained for a smooth tube to
validate the experimental procedure used before the experiments with Matrix coil wire
inserts. The results of Nusselt number and friction factor for smooth tube are compared with
the results obtained from the well-known steady state flow correlations of Dittus Boelter and
Petukhov, for the fully developed turbulent flow in circular tubes. The figures shown below
shows the comparison between the results of the present smooth tube and the correlations of
Dittus Boelter and Petukhov, respectively.

5.2 Graphs for validation

We are comparing the friction factor and Nusselt number theoretically obtained &
experimentally obtained for plane tube validation. It is observed that the theoretical values &
experimental values for friction factor & Nusselt number have error of ± 6.5 % & 12%
respectively. Hence as error is small, hence experiment is validated. This can be seen in
following graphs 5.2.1 & 5.2.2
 Validation results for friction factor for plane
tube fth
0.06 fexpt
Friction factor,ff
0.04

0.02

0
5000 7000 9000 11000
Re

Figure no.5.2.1: Validation results for friction factor for plane tube

Validation results for Nusselt number in a

plane tube
Nuexpt Nuth
40

35

30
Nu
25

20

15
5000 6000 7000 8000 9000 10000 11000
Re

Figure no.5.2.2: Validation results for friction factor for plane tube
5.3 Graphs for the comparison of Nusselt No. (Nu (exp)) without insert and
with Copper and stainless steel inserts at different Re

Nu Vs Re for copper inserts

70

60

50
Plane tube
40
Nu

Cu-12
30 Cu-10
Cu-8
20

10
6000 8000 10000 12000
Re

Figure no. 5.3.1:- Comparison of Nu for same pitch & varying density for Copper inserts

Nu Vs Re for S.S. inserts

60
55
50
45
40
Plane tube
35
Nu

SS-12
30
25 SS-10
20 SS-8
15
10
6000 8000 10000 12000
Re

Figure no. 5.3.2: Comparison of Nu for same pitch & varying density for SS inserts
 Nu Vs Re for all inserts
70

60
Plane tube
50
Cu-12
40 Cu-10
Nu

Cu-8
30
SS-12
20
SS-10
10 SS-8
6000 8000 10000 12000
Re

Figure no.5.3.3: Comparison of Nu all inserts

When inserts are placed it is been observed that Nu of copper is higher than the Stainless
steel but the Nusselt no. without inserts are proved to have lower value than the Stainless
steel and copper for all the inserts. From these graphs it’s been observed that the Nu
increases 1.42 to 2.79 times than smooth tube for Stainless steel of all the inserts of different
density and for Copper it increases by upto 1.73 to 3.18 times than smooth tube of all the
inserts of different density. Copper inserts shows better result in terms of Nusselt number
than Stainless steel, hence insert with Copper is preferred.

5.4 Graphs for the comparison of Friction Factor among without insert,
with Copper and Stainless steel inserts

Friction factor vs Re for copper inserts

0.2

0.16

0.12 Plane tube

FF

0.08 Cu-12
Cu-10
0.04
Cu-8
0
6000 8000 10000 12000
Re
 Figure no.5.4.1: Friction factor comparison for same pitch & different density for copper inserts

Friction factor vs Re for S.S. inserts

0.2

0.16

0.12 Plane tube

FF

0.08 SS-12
SS-10
0.04
SS-8
0
6000 8000 10000 12000
Re

Figure no.5.4.2: Friction factor comparison for same pitch & different density for Stainless steel inserts

Friction factor vs Re for all inserts

0.2

0.16 Plane tube

Cu-12
0.12
Cu-10
FF

0.08
Cu-8
0.04 SS-12
SS-10
0
6000 8000 10000 12000 SS-8
Re

Figure no.5.4.3: Friction factor comparison for all inserts

When inserts are placed it is been observed that friction factor of Stainless steel is same as the
copper insert because of fixed geometry but the friction factor without inserts are proved to
have lower value than the stainless steel and copper for all the inserts. From these graphs it’s
been observed that the friction factor increases 1.77 to 2.4 times than smooth tube for
Stainless steel of all the inserts of different density and for Copper it increases by only upto
1.77 to 2.4 times than smooth tube all the inserts of different density.
5.5 Graphs for the comparison of heat transfer coefficient (hexpt) among
without insert, with Copper and stainless steel inserts

h Vs Re for copper inserts

70

60

50
Plane tube
40
h

Cu-12
30 Cu-10
Cu-8
20

10
6000 8000 10000 12000
Re

Figure no.5.5.1: Heat transfer coefficient comparison for same pitch & varying density for Cu inserts

h Vs Re for S.S. inserts

60
55
50
45
40 Plane tube
35
h

SS-12
30
25 SS-10
20 SS-8
15
10
6000 8000 10000 12000
Re

Figure no.5.5.2: Heat transfer coefficient comparison for same pitch & varying density for SS inserts
 h Vs Re for all inserts
70

60
Plane tube
50
Cu-12
40 Cu-10
h

Cu-8
30
SS-12
20 SS-10
SS-8
10
6000 8000 10000 12000
Re

Figure no.5.5.3: Heat transfer coefficient comparison for all inserts

When inserts are placed it is been observed that hexpt of copper is higher than the stainless
steel but the heat transfer coefficient without inserts are proved to have lower value than the
SS and copper for all the inserts. From these graphs it’s been observed that the hexpt increases
1.42 to 2.79 times than smooth tube for SS of all the inserts of different density and for
Copper it increases by upto 1.73 to 3.18 times than smooth tube all the inserts of different
density Copper inserts shows better result in terms of heat transfer coefficient than SS hence
insert with Copper is preferred.

5.6 Graphs for the comparison of heat transfer enhancement (η) among
without insert, with Copper and stainless steel inserts
The Performance Evaluation criteria is most deciding parameter in terms of heat transfer
enhancement and friction factor to select which type of insert has optimum value in the above
said parameters.

( ⁄ )
η= .333
( ⁄ )

The performance evaluation criteria (PEC) is another most important parameter which
decides the optimized value of heat transfer enhancement and friction factor and to select the
insert based on the above optimized values. When the parameters like Nusselt number and
friction factor are obtained through the experimentation work for all the above inserts of
stainless steel and after putting these values in above formula the PEC are calculated for each
and every inserts. These PEC are plotted and certain results can be concluded from the below

Enhancement vs Re for copper inserts

2.4

2.15
Enhancement
Cu-12
1.9
Cu-10
1.65 Cu-8

1.4
6000 8000 10000 12000
Re
graph.

Figure no.5.6.1: Enhancement for Copper for same pitch with different density

Enhancement vs Re for S.S. inserts

2.1

1.85
Enhancement

1.6 SS-12
SS-10
1.35 SS-8

1.1
6000 8000 10000 12000
Re

Figure no.5.6.2: Enhancement for SS for same pitch with different density

The PEC values for all the inserts are above one which indicates that the experimental set-up
and measurement technique are accurate. For SS inserts of different density8,10,12 no of
turns per pitch shows upto 2.08 times greater enhancement than plane tube. But copper shows
still higher enhancement. Of all inserts the copper insert of different density 8,10,12 no of
turns per pitch shows highest enhancement of 2.37 times than plane tube.
 Enhancement vs Re for all inserts
2.5

2.3

2.1 Cu-12
Enhancement

1.9 Cu-10

1.7 Cu-8

1.5 SS-12
SS-10
1.3
SS-8
1.1
6000 7000 8000 9000 10000 11000 12000 13000
Re

Figure no.5.6.3: Enhancement for all inserts

Through above graph it is also observed for each insert that, with rise in Reynolds number the
enhancement goes on decreasing.
 CHAPTER 6
CFD Analysis
6.1 CFD Analysis process
The general process for performing a CFD analysis is outlined below so as to provide a
reference for understanding the various aspects of a CFD simulation. The process includes:

1. Formulate the Flow Problem

2. Model the Geometry and Flow Domain
3. Establish the Boundary and Initial Conditions
4. Generate the Grid
5. Establish the Simulation Strategy
6. Establish the Input Parameters and Files
7. Perform the Simulation
8. Monitor the Simulation for Completion
9. Post-process the Simulation to get the Results
10. Make Comparisons of the Results
11. Repeat the Process to Examine Sensitivities
12. Document

6.2 CFD Analysis Steps:-

1)Formulate the Flow Problem

The first step of the analysis process is to formulate the flow problem by seeking
answers to the following questions:
 What is the objective of the analysis?
 What is the easiest way to obtain those objective?
 What geometry should be included?
 What are the free stream and/or operating conditions?
 What dimensionality of the spatial model is required? (1D, quasi-1D, 2D,
axisymmetric, 3D)
 What should the flow domain look like?
 What temporal modeling is appropriate? (steady or unsteady)
 What is the nature of the viscous flow? (inviscid, laminar, turbulent)
 How should the gas be modeled?
2) Model the Geometry and Flow Domain
The body about which flow is to be analyzed requires modeling. This generally
involves modeling the geometry with a CAD software package. Approximations of
the geometry and simplifications may be required to allow an analysis with reasonable
effort. Concurrently, decisions are made as to the extent of the finite flow domain in
which the flow is to be simulated. Portions of the boundary of the flow domain
coincide with the surfaces of the body geometry. Other surfaces are free boundaries
over which flow enters or leaves. The geometry and flow domain are modeled in such
a manner as to provide input for the grid generation. Thus, the modeling often takes
into account the structure and topology of the grid generation.
3)Establish the Boundary and Initial Conditions
Since a finite flow domain is specified, physical conditions are required on the
boundaries of the flow domain. The simulation generally starts from an initial solution
and uses an iterative method to reach a final flow field solution.
4)Generate the Grid
The flow domain is discretized into a grid. The grid generation involves defining the
structure and topology and then generating a grid on that topology. Currently all cases
involve multi-block, structured grids; however, the grid blocks may be abutting,
contiguous, non-contiguous, and overlapping. The grid should exhibit some minimal
grid quality as defined by measures of orthogonality (especially at the boundaries),
relative grid spacing (15% to 20% stretching is considered a maximum value), grid
skewness, etc... Further the maximum spacing should be consistent with the desired
resolution of important features. The resolution of boundary layers requires the grid to
be clustered in the direction normal to the surface with the spacing of the first grid
point off the wall to be well within the laminar sub layer of the boundary layer. For
turbulent flows, the first point off the wall should exhibit a y+ value of less than 1.0.

5)Establish the Simulation Strategy

The strategy for performing the simulation involves determining such things as the
use of space-marching or time-marching, the choice of turbulence or chemistry
model, and the choice of algorithms.
6)Establish the Input Parameters and Files
 A CFD codes generally requires that an input data file be created listing the values of
the input parameters consisted with the desired strategy. Further a grid file containing
the grid and boundary condition information is generally required. The files for the
grid and initial flow solution need to be generated.
7)Perform the Simulation
The simulation is performed with various possible with options for interactive or
batch processing and distributed processing.
8)Monitor the Simulation for Completion
As the simulation proceeds, the solution is monitored to determine if a "converged"
solution has been obtained, which is iterative convergence.

6.3 CFD Post-Process of Simulation to Get Results:-

1. Make Comparison of Result :-The computed flow properties are then compared to
results from analytic, computational, or experimental studies to establish the validity of the
computed results.
2.Repeat the Process to Examine Sensitivities:-The sensitivity of the computed results
should be examined to understand the possible differences in the accuracy of results and or
performance of the computation with respect to such things as dimensionality,flow
conditions,initial conditions, marching strategy, algorithms, grid topology and density,
turbulence model, flux model,boundary conditions.

6.4 Computational Analysis in ANSYS-FLUENT:-

The Geometry model is created in ANSYS Design modeler and then I imported in
the ANSYS Meshing to generate the hybrid mesh. The core product of Ansys is its ANSYS
Workbench Module R 15.0. This code is based on the Finite volume method and is capable
of performing flow,thermal, radiation ,turbomachinary,combustion and Multiphase. Our
requirement here is thermal analysis of the model.
FLUENT is a commercial Computational Fluid Dynamics (CFD) program, used
to simulate fluid flow in a variety of applications. The ANSYS-FLUENT product allows
testing systems in a videlrtual environment. -
6.5 Model construction &mesh generation :-

We now begin with the pre-processing of the model. The actual processing involves finite
element method for which it is required that the given model be discretized. This is done in
the pre-processing with a few important steps before and after Discretization; also known as
meshing of the model. These procedures are:
Tube with coils inserted geometry is created into design Modeler and Mesh generation is
completed into ANSYS Meshing
Define the meshing parameters, used the Advanced size function to refine mesh near to
curvature region , defined max element size, min element size. Boundary layers are generated
over the plate, defined the initial height, number of layer and growth ratio.

Fig.6.5.1 CFD Modular geometry creation

 Fig.6.5.2 CFD Geometry coil details
ANSYS Meshing is physics and Solver based mesh generation tool . CFD as a
physics and Fluent as a solver is setted for mesh generation. Defined max element size, max
face size and min element size. Defined Advanced size function as curvature. Mesh type is a
tetra and prism for boundary layer generation. Total element count is 5.6 million, with Max
skewness is 0.91.

Fig.6.5.3 CFD Mesh

Fig.6.5.4 CFD mesh details

6.6 CFD solver setup
ANSYS Fluent is a CFD solver. Boundary conditions are defined
 Inlet – Velocity Inlet
  Outlet – pressure outlet
 Walls – apply heat flux on circular tube surface
 Fluid Material – Air ( Density = 1.135, Thermal Conductivity =0.026)
 Solid Material – copper and SS metal
 TurbulenceModel - K-epsilon, realizable, enhanced wall treatment model
 Energy equation – ON
 Solution Method – Second Order
 Initialization from Inlet condition
 Convergence residual monitors upto 1e-3.

6.7 CFD Result - Post-Processing:--

The results that are obtained after the processing is over can be viewed in the FLUENT
post processor. In this, various parameters can be graphically seen. The velocity vectors,
temperature contours, Area weighted avg heat transfer coefficient etc and quantitative
calculate surface intergral data e.g. Area wrighted AvgNusselt Number, Temperature, surface
heat transfer coefficient etc are some of the major parameters that can be viewed.. The view
chart of the post processor gives details of the entire procedure which can be summarized as
follows:

Fig6.7.1 Temp distribution on plane tube at V=7.18m/s and heat flux = 554.16 on tube
surface
Fig.6.7.2 Contour of Nu Number on plane tube. Nu= 35.12 , V=7.18m/sec ,q = 554.16 W/m^

Fig.6.7.3 Temp distribution on plane tube at V=3.99/s and heat flux 485.34 on tube
surface

Fig.6.7.4 Contour of Nu No. on plane tube. Nu= 22.08 , V=3.99m/sec ,q = 485.34

W/m^2
Fig.6.7.5 Temp distribution on pipe surface after coil inserted at V=8.66/s and heat flux
704.96 on tube surface

Fig. 6.7.6 Temp distribution on coils at V=8.66/s and heat flux 704.96

Fig.6.7.7 Contour of Nusselt Number on plane tube. Nu= 56.72 , V=8.66m/sec ,q = 704.96
W/m^2
6.8 Results and Discussions of graphs with and without inserts using
CFD Analysis:-

Nu CFD vs Re
70
60
50
40 Cu-8
Nu

30 Cu-10
20 Cu-12
10 Plain tube
0
6000 8000 10000 12000 14000
Re

Figure no. 6.8.1: Comparison of Nu CFD for same pitch & varying density for SS inserts

Nu CFD vs Re
60

50

40
SS-8
30
Nu

SS-10
20
SS-12
10 Plain tube
0
6000 8000 10000 12000 14000
Re

Figure no. 6.8.2 Comparison of Nu CFD for same pitch & varying density for SS inserts

When CFD analysis is done it is been observed that Nu of copper is higher than the
Stainless steel but the Nusselt no. without inserts are proved to have lower value than the
Stainless steel and copper for all the inserts. From graph it shows that Nu increases with
increase in Reynolds number. From observation table error in CFD Nu no. to Experimental
Nu is maximum up to 5.12% for SS inserts and is maximum up to 2.89% for Cu inserts.
 CHAPTER 7
CONCLUSIONS AND FUTURE SCOPE
7.1 Results Discussion
The inserts are placed inside the test pipe and the experiment was conducted with
varying density and material. It is observed that with inserts there is increase in Nusselt
number by upto 2.35time as compared to the plain tube however it was observed that due to
the nature of inserts the friction factor increased as compared with plain tube.. The modelling
of experimental results of heat transfer from a heat exchanger equipped with Matrix coil wire
inserts, placed in a pipe, was studied by the use of CFD This method was used to gain
relationship between three input parameters namely Reynolds number , density and
temperature, and the friction factor , Nusselt number as output variable.
The results obtained from the experiment which is discussed above are concluded below
and an optimum insert is obtained which is used for this experimental set up.
1. It is observed that with an increase in the Reynolds number (Re) ranging from 6000 to
13000, the heat transfer coefficients increases for matrix coil wire inserts by72% to
218% for copper and 42% to 179% for stainless steel with respect to plain tube
whereas the friction factor decreases.
2. When theoretical and experimental values are compared of Nusselt number then the
copper insert with density 12 nos of turns per pitch gives 218% rise in Nusselt
number and Nu decreases with density of material.
3. When theoretical and experimental values are compared copper insert then friction
factor values are compared then copper insert with density 12 nos of turns per pitch
gives 2.89 times rise as compared plane tube.But Nu is also increasing hence
proving the insert to be better in terms of heat transfer enhancement and also at lesser
pumping power.
4. The increase in pressure drop by increasing density is not as significant as the
increase in Nusselt number. The optimum value obtained for minimum pressure drop
is for copper with density 12 nos of turns per pitch .
5. Error in CFD Nu no. to Experimental Nu is maximum up to 5.12% for SS inserts and
is maximum up to 2.89% for Cu insert. It also indicates validation of our experimental
setup
7.2 Future scope

As there are no limits for improvements in any kind of work or nothing is best. There
is always scope for improvements in present work. So, coil wire insert is not an exception.
This may lead to better design of coil wire inserts with different density.Other possible
modifications are as listed below:

1. We can reduce number of pitch distance to get more optimum value.

2. Experiments are also possible with varying the density of inserts.
3. We can try some modifications in the geometry of Matrix coil wire with the help of CFD
analysis.
4. We can try the same geometry with different materials and compare the results with the
existing material.
5. We can apply CFD programming in various heat exchanger so as to avoid manual
interpretation and minimize the time
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 APPENDIX I
OBSERVATION TABLES
1] Validation test (plane tube)

% %
Ts Tb ha hf m* q Nuth Nuexp Re fth fexp
error error

K K m m kg/sec W/m^2
323.60 308.35 48.46 2.32 0.0043 554.16 35.16 36.34 3.35 10963.77 0.0306 0.0328 6.96
326.75 309.50 32.60 1.61 0.0035 535.47 30.01 31.04 3.45 8992.48 0.0324 0.0337 4.12
332.12 311.60 18.50 1.07 0.0027 478.46 23.92 23.32 -2.52 6774.67 0.0352 0.0396 12.64
333.97 311.35 14.98 0.89 0.0024 485.35 21.98 21.46 -2.38 6095.41 0.0363 0.0408 12.35
341.07 312.25 11.45 0.71 0.0021 520.38 19.75 18.06 -8.55 5330.28 0.0378 0.0427 12.84

2] Plane Tube calculations

Ts Tb ha hf m* q h Nuexpt Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

325.13 309.50 36.12 2.32 0.0037 498.12 31.86 31.86 6.20 9466.09 0.044
325.98 309.30 27.31 1.96 0.0032 478.73 28.70 28.70 5.39 8231.13 0.049
327.73 309.65 21.15 1.61 0.0029 476.39 26.34 26.34 4.74 7242.43 0.052
330.07 309.80 14.10 1.25 0.0023 417.63 20.61 20.61 3.87 5913.42 0.061
338.47 311.90 7.05 0.71 0.0017 353.21 13.30 13.30 2.74 4181.42 0.069

3] SS-08 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

325.42 311.05 70.485 8.029 0.0052 650.0330 45.2459 45.246 8.661 13222.81 0.0780
327.67 310.95 58.150 7.315 0.0047 706.8430 42.2837 42.284 7.867 12010.21 0.0861
328.35 311.20 44.053 6.423 0.0041 665.8937 38.8276 38.828 6.847 10453.55 0.0998
330.87 312.55 26.432 5.531 0.0032 633.5358 34.5879 34.588 5.304 8097.28 0.1433
334.27 312.90 17.621 3.925 0.0026 585.9452 27.4233 27.423 4.330 6611.40 0.1525
4] SS-10 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

322.37 309.80 70.48 8.207 0.0052 659.188 52.455 52.46 8.66 13222.81 0.0797
322.65 309.40 58.15 7.672 0.0047 681.896 51.464 51.46 7.87 12010.21 0.0903
323.68 309.30 44.05 6.601 0.0041 680.370 47.303 47.30 6.85 10453.55 0.1026
325.47 310.25 26.43 5.709 0.0032 655.962 43.108 43.11 5.30 8097.282 0.1479
329.02 311.15 17.62 4.104 0.0026 581.368 32.539 32.54 4.33 6611.403 0.1595

5] SS-12 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

322.38 309.85 70.48 8.564 0.0052 668.34 53.33 53.33 8.66 13222.81 0.083
322.85 309.45 58.15 7.850 0.0047 706.84 52.75 52.75 7.87 12010.21 0.092
323.67 309.65 44.05 6.780 0.0041 687.61 49.06 49.06 6.85 10453.55 0.105
324.97 310.45 26.43 6.066 0.0032 622.32 42.87 42.87 5.30 8097.28 0.157
328.83 311.60 17.62 4.282 0.0026 640.88 37.19 37.19 4.33 6611.40 0.166

6] Cu-08 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

323.05 310.25 70.48 8.029 0.0052 704.97 55.08 55.08 8.66 13222.81 0.0780
323.32 310.15 58.15 7.315 0.0047 706.84 53.68 53.68 7.87 12010.21 0.0861
324.95 310.50 44.05 6.423 0.0041 709.32 49.09 49.09 6.85 10453.55 0.0998
326.27 311.15 26.43 5.531 0.0032 655.96 43.39 43.39 5.30 8097.28 0.1433
330.07 312.40 17.62 3.925 0.0026 659.19 37.31 37.31 4.33 6611.40 0.1525
7] Cu-10 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

321.950 309.75 70.48 8.207 0.0052 686.65 56.28 56.28 8.66 13222.81 0.0797
322.300 309.5 58.15 7.672 0.0047 698.53 54.57 54.57 7.87 12010.21 0.0903
322.967 309.6 44.05 6.601 0.0041 680.37 50.90 50.90 6.85 10453.55 0.1026
324.867 310.35 26.43 5.709 0.0032 644.75 44.41 44.41 5.30 8097.28 0.1479
327.867 311.05 17.62 4.104 0.0026 636.30 37.84 37.84 4.33 6611.40 0.1595

8] Cu-12 Insert Experimental Results

Ts Tb ha hf m* q h Nu Velocity Re fexp

K K m m kg/sec W/m^2 W/m^2K m/s

321.82 310.00 70.48 8.564 0.0052 695.81 58.88 58.88 8.66 13222.81 0.083
322.30 309.95 58.15 7.850 0.0047 706.84 57.23 57.23 7.87 12010.21 0.092
323.50 310.25 44.05 6.780 0.0041 716.56 54.08 54.08 6.85 10453.55 0.105
324.73 311.05 26.43 6.066 0.0032 667.17 48.76 48.76 5.30 8097.28 0.157
329.20 312.65 17.62 4.282 0.0026 700.39 42.32 42.32 4.33 6611.40 0.166

9] Plain tube CFD Results

Area Wt
heat flux Bulk Temp Nu % error
Velocity Avg Area wt Avg Temp Re
(q) (Tb) Experimental in Nu
Nu(CFD)
m/sec W/m^2 K K
7.18 554.16 308.5 35.12 324.4 10963.77 36.338 -3.4694
5.89 535.46 309 30.09 327.3 8992.481 31.041 -3.16208
4.43 478.45 311.6 24.12 332.8 6774.672 23.320 3.315294
3.99 485.34 311.35 22.08 334.3 6095.413 21.460 2.808854
3.49 520.38 312.25 20.23 342.7 5330.284 18.058 10.73458
10] SS-08 coil Insert CFD Results

Area Wt
heat flux Bulk Temp Nu % error in
Velocity Avg Area wt Avg Temp Re
(q) (Tb) Experimental Nu
Nu(CFD)
m/sec W/m^2 K K
8.66 704.96 310.25 46.69 327.340 13222.81 45.246 3.093
7.86 706.84 310.15 43.17 327.980 12010.21 42.284 2.053
6.84 709.32 310.5 39.14 329.4 10453.55 38.828 0.798
5.3 655.96 311.15 34.9 331.56 8097.282 34.588 0.894
4.33 659.18 312.4 28.21 335.45 6611.403 27.423 2.789

11] SS-10 Coil Insert CFD Results

Area Wt Nu
heat flux Bulk Temp % error in
Velocity Avg Area wt Avg Temp Re Experiment
(q) (Tb) Nu
Nu(CFD) al
m/sec W/m^2 K K
8.66 704.96 310.25 54.45 323.100 13222.81 52.455 3.663
7.86 706.84 310.15 52.8 323.400 12010.21 51.464 2.531
6.84 709.32 310.5 48.6 323.76 10453.55 47.303 2.669
5.3 655.96 311.15 44.1 326.6 8097.282 43.108 2.249
4.33 659.18 312.4 34.55 330.8 6611.403 32.539 5.820

12] SS-12 Coil Insert CFD Results

Area Wt Nu
heat flux Bulk Temp % error in
Velocity Avg Area wt Avg Temp Re Experiment
(q) (Tb) Nu
Nu(CFD) al
m/sec W/m^2 K K
8.66 704.96 310.25 56.7 325.100 13222.81 53.33 5.952
7.86 706.84 310.15 54.51 324.800 12010.21 52.75 3.230
6.84 709.32 310.5 50.2 325.42 10453.55 49.06 2.278
5.3 655.96 311.15 44.34 325.86 8097.282 42.87 3.316
4.33 659.18 312.4 39.2 330.33 6611.403 37.19 5.132
13] Cu-08 Coil Insert CFD Results

Nu
heat flux Bulk Temp Area Wt Avg Area wt Avg % error in
Velocity Re Experim
(q) (Tb) Nu(CFD) Temp Nu
ental
m/sec W/m^2 K K
8.66 704.96 310.25 56.72 325.080 13222.81 55.08 2.899
7.86 706.84 310.15 54.12 325.400 12010.21 53.68 0.805
6.84 709.32 310.5 49.86 326.72 10453.55 49.09 1.548
5.3 655.96 311.15 43.43 327.12 8097.282 43.39 0.085
4.33 659.18 312.4 36.53 330.95 6611.403 37.31 -2.142

14] Cu-10 Coil Insert CFD Results

heat flux Bulk Temp Area Wt Avg Nu % error

Velocity Area wt Avg Temp Re
(q) (Tb) Nu(CFD) Experimental in Nu
m/sec W/m^2 K K
8.66 704.96 310.25 57.14 322.310 13222.81 56.28 1.500
7.86 706.84 310.15 54.6 322.600 12010.21 54.57 0.050
6.84 709.32 310.5 51.4 323.1 10453.55 50.90 0.972
5.3 655.96 311.15 44.9 325.1 8097.282 44.41 1.082
4.33 659.18 312.4 38.1 328.69 6611.403 37.84 0.689

15] Cu-12 Coil Insert CFD Results

heat flux Bulk Temp Area Wt Avg Nu % error

Velocity Area wt Avg Temp Re
(q) (Tb) Nu(CFD) Experimental in Nu
m/sec W/m^2 K K
8.66 704.96 310.25 57.14 322.310 13222.81 56.28 1.500
7.86 706.84 310.15 54.6 322.600 12010.21 54.57 0.050
6.84 709.32 310.5 51.4 323.1 10453.55 50.90 0.972
5.3 655.96 311.15 44.9 325.1 8097.282 44.41 1.082
4.33 659.18 312.4 38.1 328.69 6611.403 37.84 0.689
 ANNEXTURE-I

Sample calculations of without insert

Observation table of without insert

Inclined
Sr Manometer
No.
Temperatures oC Manometer
Difference
Reading
T1 T2 T3 T4 T5 T6 T7 T8 hw hf
1 32.7 42.6 48.9 52.6 56.8 57.6 54.3 40.3 41 3.25

As per the observation table shown in methodology experimentation was carried out
and temperature and manometer difference values obtained are put in the table 4.2.1. This
manometer difference indicates change in mass flow rate operated by the valve next to the
test section, this increase in manometric head indicates increase in mass flow rate and this
causes increase in Reynolds number. As Reynolds number increases the friction factor has to
reduce.

Sample calculations of without insert at 41mm head

1. Ts = (T2+T3+T4+T5+T6+T7)/6
Ts = 325.133 0K
2. Tb = (T1+T8)/2
Tb = 309.5 0K
From Table of properties of air
 ρa = 1.135, Pr = 0.7602, ν = 1.703*10-5
2∗g∗ ∗ρ
3. Qa = 0.615*Ao* ρa

Qa = 0.615*2.0106*10-4* ∗ .81 ∗ 1000 ∗ 0.041/1.1

Qa = 0.003292 m3/s

4. ̇ = Qa*ρa
̇ = 0.003813 * 1.135

̇ = 0.004328 kg/s
5. V= Qa /A

V= 7.18127 m/s

V∗D
6. Re = ν

7. 27∗ . 26
Re = .7 ∗ ^−

Re = 10963.77

7. h =(1.82 * log10 Re -1.64)-2

fth= 0.0306417

8. Nu h = 0.023 Re0.8 Pr0.4

Nuth = 35.16
Δ
9. f=
∗

fexp = 0.0327

10. Nu = h /k Nu exp = 36.34

Showing mass flow rate, friction factor and Nusselt number of without insert

m
Re fexpt Nu
(kg/s)

10963.77 0.004328 0.0327 36.34