SUMMARY

The experiment was intended to study heat transfer coefficient in a double pipe heat exchanger.
In this process the individual and overall heat transfer coefficient was calculated, variation of
heat transfer coefficient with Reynolds number (Re) and fluid velocity(v) were studied and
finally the estimated and experimental heat transfer coefficients were compared and analyzed.
Hot water flowed through the annular region whereas hot steam through the inner pipe.
Continuous heat transfer (Convection, Conduction) between the two fluids resulted in
temperature increase for water and condensation for steam. For three different steam pressures,
data were taken at four different water flow rates. Condensate was collected for a fixed amount
of time. The amount of water flowing for a fixed amount of time was observed in the flow meter.
The values of heat transfer coefficients for water side were 2138.73-3107.15 W/m2.oC and for
steam side they were 7790.03-8058.69 W/m2.oC. The theoretical values of overall heat transfer
coefficients were 943.49-2043.09W/m2.0C whereas experimental value ranged from 834.84-
1397.32 W/m2.0C. Three graphs Nusselt number vs Reynold Number, Water side heat transfer
coefficient vs Velocity of water and Wilson plot were plotted and the results were analyzed. The
dirt factors were found to be 3.1×10−4 m2.K/W (5psig), .6 ×10−4 m2.K/W (10psig) and 3.3
−4
×10 m2.K/W (15psig) from Wilson plot.

1
EXPERIMENTAL SETUP

Figure 1: Schematic Diagram of Double Pipe Heat Exchanger

The experimental setup consists of a double pipe heat exchanger whose tube length is 7´4´´. The
inner tube of the heat exchanger is a Schedule 40 pipe with nominal diameter 1´´. The steam
required for the experiment comes from the boiler kept in Boiler and Steam Laboratory of
Mechanical Department, BUET.

2
RESULTS AND DISCUSSIONS

The steam pressure of the inlet steam was maintained at 5 psig,10 psig and 15 psig respectively
with the help of pressure guage and pressure control valve. For each inlet steam pressure, the
water flow was varied 4 times to get data for 4 different water flow rate. Water flow rate was
controlled using the water control valve. Volume of water flowing through the pipe was
observed for a definite time from the flow meter with a stopwatch. For a definite steam pressure
and a definite water flow rate, the water inlet and outlet temperatures were determined using
thermometers. The mass of condensate formed during a definite time was observed using a
weight machine and a stopwatch. The following observations were found,

Table 1: Observed data for the study of heat transfer co-efficient in a Double Pipe Heat
Exchanger

Steam No. of Water temperature Water Condensate

Pressur observatio Inlet, T1 Outlet, T2 Volume Time Weight Time
e n (℃) (℃ ) (L) (s) (kg) (s)
(psig)
1 28.00 46.50 10.00 40.82 0.90 120
2 28.00 43.00 10.00 30.90 1.10 120
5
3 28.00 41.50 10.00 26.00 1.10 120
4 28.00 41.50 10.00 27.00 1.10 120
1 28.00 53.00 10.00 68.00 0.75 120
2 28.00 45.00 10.00 30.50 1.10 120
10
3 28.00 42.50 10.00 24.31 1.15 120
4 28.00 42.00 10.00 24.09 1.20 120
1 28.00 53.50 10.00 54.00 0.90 120
2 28.00 46.00 10.00 34.50 1.15 120
15
3 28.00 39.50 10.00 24.00 1.35 120
4 28.00 39.00 10.00 15.00 1.45 120

3
The saturation temperature, Ts and heat of condensation, λs are determined for the maintained
Steam pressure. Mass flow rate of condensate and water are obtained using the following
formula,
Mass flow rate of water, Mw = W w × ρm

Volume of water ( L)
=
Water collection time ¿ ¿ ¿

Mass flow rate of condensate, MC = Mass of condensate collected ¿ ¿ ¿

Table 1 - Data of saturation temperature, heat of condensation and mass flow rate of
condensate and water

Steam No. of Saturation Heat of Mass flow Mass flow

pressure observation temperature, condensation rate of rate of
(psig) Ts λs condensate water
(℃) (kJ/kg) Mc Mw
(kg/s) (kg/s)
1 0.0075 0.24
2 0.0092 0.32
5 108.39 2199.47
3 0.0092 0.38
4 0.0092 0.37
1 0.0063 0.15
2 0.0092 0.33
10 115.20 2215.48
3 0.0096 0.41
4 0.0100 0.41
1 0.0075 0.18
2 0.0096 0.29
15 120.96 2234.06
3 0.0113 0.41
4 0.0121 0.66

4
The temperature of water from T1 to T2 as it passes from inlet to outlet. So, all properties of water
(T 1+T 2)
flow are to be determined at a mean temperature Tm = . The value of density(ρm),
2
viscosity(µm), thermal conductivity(km) and specific heat (Cp) are obtained at Tm from literature.
T s+T m
The wall temperature, Tw is obtained using the formula Tw= .
2

Table 3 - Data for water flow properties at mean temperature

Steam No. of Mean Wall Density Viscosity Thermal Specific

pressure observ temperature temperature ρm µm×104 conductivity heat
(psig) ations Tm (℃) Tw (℃) (kg/m3) (kg/m.s) km Cp
(W/m2.℃) (J/kg.K)
1 37.25 72.82 993.24 6.91 0.6266 4178
2 35.50 71.95 993.86 7.15 0.6238 4178
5
3 34.75 71.57 994.12 7.26 0.6226 4178
4 34.75 71.57 994.12 7.26 0.6226 4178
1 40.50 77.85 992.03 6.50 0.6316 4179
2 36.50 75.85 993.51 7.01 0.6254 4178
10
3 35.25 75.22 993.95 7.19 0.6234 4178
4 35.00 75.10 994.03 7.22 0.623 4178
1 40.75 80.85 991.93 6.47 0.6319 4179
2 37.00 78.98 993.33 6.94 0.6262 4178
15
3 33.75 77.35 994.46 7.41 0.621 4178
4 33.50 77.23 994.54 7.44 0.6206 4178

5
 (Volumetric flow rate of water )W w
The velocity of water flow, v= is determined. Then the value
(Flow areaof inner pipe) A i
of Reynolds number (Re), Prandtl number(Pr), Nusselt number(Nu) and Water side heat transfer
coefficient, hi is determined using the following formula,

Di × ρ× v
Re = ;
μm

C P × μm
Pr = ;
km

1
Nu=0.023 × ℜ0.8 × Pr 3 ;

km
hi = 0.023 × D i ×(Re)0.8 ×(Pr)1/3 (Dittus-Boelter equation)

Table 4 - Data for water flow properties at mean temperature (continued)

Steam No. of Velocity of Reynolds Prandtl Nusselt Water side heat

pressure observat water, number, number, number, transfer
(psig) ion v Re Pr Nu coefficient,
(m/s) hi (W/m2.℃)

1 0.44 16823.75 4.61 91.96 2138.73

2 0.58 21489.76 4.79 113.31 2633.50
5
3 0.69 25168.98 4.87 129.30 2913.54
4 0.66 24236.79 4.87 125.46 3075.52
1 0.26 10730.01 4.30 62.70 2595.94
2 0.59 22196.03 4.68 115.42 2836.93
10
3 0.74 27182.81 4.82 137.00 2996.77
4 0.74 27297.39 4.84 137.72 3092.39
1 0.33 13573.63 4.28 75.55 2663.31
15 2 0.52 19811.13 4.63 105.00 2935.85
3 0.75 26733.57 4.98 136.72 3022.91

6
 4 1.19 42561.50 5.01 198.72 3107.15
Film condensation occurs at the steam side flow. Film temperature, Tf= Ts-0.75 × (Ts-Tw) is
determined. Density (ρf), viscosity(µf), Thermal conductivity (Kf) are determined at Tf from
literature. Condensation heat transfer coefficient is determined using the following formula,

k 3 . ρ 2 . g . λS
f f 0. 25
0 . 725×[ ]
ho = D 0 (T S −T W )μ f

Table 5 - Data for steam properties at film temperature

Steam No. of Film Density Viscosity Thermal Condensation
pressure observation temperature ρf µf×104 conductivity heat transfer
(psig) , Tf (kg/m3) (kg/m.s) kf (W/m.℃) coefficient,
(℃) ho (W/m2.℃)
1 81.433 970.740 3.4746 0.669 7999.15
2 80.870 971.156 3.5034 0.669 7932.82
5
3 80.589 971.364 3.5157 0.670 7901.23
4 80.308 971.572 3.5157 0.670 7901.23
1 85.312 967.869 3.2512 0.673 8058.69
2 84.937 968.147 3.3052 0.673 7920.56
10
3 84.749 968.285 3.3221 0.664 7878.77
4 84.749 968.285 3.3256 0.664 7870.69
1 89.097 965.810 3.1183 0.671 8021.07
2 88.722 966.016 3.1691 0.672 7894.98
15
3 88.628 966.068 3.2130 0.672 7794.04
4 88.534 966.120 3.2102 0.672 7790.03

7
The rate of heat transfer in both sections, the mean rate of heat transfer and the experimental
overall heat transfer are calculated using the following equations,

Rate of heat taken by water, Qw = Mw × Cp× (T2-T1) ;

Rate of heat given by steam, Qc = Mc × λs ;

QW +QC
Mean rate of heat flow, Qm = ;
2
Qm
Experimental overall heat transfer coefficient, UOE =
Δ T lm . A 0
Δ T 1−Δ T 2
where, ΔTlm = ΔT1
ln
ΔT2

Table 6 - Data for experimental heat transfer coefficients

Steam Observation Rate of Rate of Mean rate Log mean Experimental

pressure no. heat taken heat given of heat temperature overall heat
(psig) up by up by transfer difference, transfer
water steam, Qm (W) ΔTlm(℃) coefficient
Qw (W) Qc (W) UOE(W/m2.℃)
1 18807.08 16496.03 17651.55 70.74 1059.86
2 20157.02 20161.81 20159.42 72.63 1178.86
5
3 21565.90 20161.81 20863.86 73.44 1206.74
4 20767.17 20161.81 20464.49 73.44 1183.64
1 15241.52 13846.75 14544.13 74.00 834.84
2 23136.08 20308.57 21722.32 78.39 1176.95
10
3 24769.43 21231.68 23000.56 79.73 1225.31
4 24135.66 22154.80 23145.23 79.99 1228.92
1 19574.91 16755.45 18165.18 79.52 970.20
2 21652.87 21409.74 21531.30 83.63 1093.51
15
3 19908.67 25133.18 22520.92 87.08 1098.50
4 30471.38 26994.89 28733.14 87.34 1397.32

8
9
The theoretical overall heat transfer coefficient, UOT is determined using the following formulae,

UOT = ¿

1
∧1
The value of 1 , U OT are calculated for the ease of plotting the Wilson plot.
0.8
U OE Vm

Table 7 - Data for calculation of theoretical heat transfer coefficients

Steam Observation Theoretical 1 4 1 4 1

× 10 × 10
U OE U OT 0.8
Vm
pressure no. overall heat
(psig) transfer
coefficient
UOT(W/m2.℃)
1 1256.18 9.43523 7.96065 1.93
2 1450.08 8.48276 6.89616 1.55
5
3 1581.65 8.28677 6.32251 1.35
4 1550.35 8.44849 6.45017 1.39
1 943.49 11.97838 10.59889 2.91
2 1470.71 8.49651 6.79943 1.53
10
3 1642.84 8.16122 6.08703 1.28
4 1647.35 8.13722 6.07035 1.27
1 1091.46 10.30713 9.16201 2.42
2 1377.81 9.1449 7.25789 1.69
15
3 1632.91 9.10331 6.12405 1.26
4 2043.09 7.15654 4.89454 0.87

From Table 6 and 7 it can be seen that the theoretical values of overall heat transfer coefficient
are higher than experimental overall heat transfer coefficients for every observation. In
theoretical experiment, dirt factor and other heat loss factors are not considered but in reality
they are accountable for reduction in overall heat transfer than theoretical values. Dirt factor
increases due to buildup of layer of dirt or other fouling substance on the tube surfaces and in the

10
tubes of the heat exchanger over the period of operations. The heat exchanger used by us is old
enough to

account for fouling. Besides a considerable amount of heat is lost to the surroundings although
the exchanger was fully insulated.

Logarithmic plot of Nusselt Number (Nu) versus Reynolds Number (Re):

Nusselt number and water side heat transfer coefficient for the experiment is found using
Dittus-Boelter equation. This equation is valid for fully developed turbulent flow in smooth
tubes for fluids with Prandtl numbers ranging from about 0.6 to 100 and with moderate
temperature differences between wall and fluid conditions. In order to use the equation,
Reynolds number(to ascertain whether the flow is turbulent) and Prandtl number(to ascertain the
range of applicability) are checked for different observations and are found to be comply with
the conditions.

From Dittus-Boelter equation, Nu = 0.023(Re)0.8(Pr)1/3.

Taking logarithm in both side,

log(Nu) = log(0.023(Pr)1/3) + 0.8log(Re)……………………….….(1)

The final equation is a straight line in the form of y= mx+c with a slope, m=0.8. This
means if Nusselt number is plotted against Reynolds number on a logarithmic plot, it will give a
straight line with a slope of 0.8.
All the three Nusselt Number with Reynolds Number experiment plot are straight line and has
slope equaling to 0.85, 0.84, 0.84 for 5,10,15 psi steam pressure respectively which is quiet
desirable to our theoretical consideration.

11
 500.00

Nusselt Number (Nu)

50.00
10000 100000

Reynolds Number (Re)

Figure 2:Variation of Nusselt Number with Reynolds Number (Steam Pressure of 5 psig)

500.00
Nusselt Number (Nu)

50.00
5000 50000
Reynolds Number (Re)

Figure 3:Variation of Nusselt Number with Reynolds Number(Steam Pressure of 10 psig)

12
 1000.00
Nusselt Number (Nu)

100.00

10.00
10000 100000
Reynolds Number (Re)

Figure 4: Variation of Nusselt Number with Reynolds Number(Steam Pressure of 15 psig)

Logarithmic plot of water side heat transfer coefficient (hi) versus velocity of water

km
From Dittus-Boelter equation, hi = 0.023 × D i ×(Re)0.8 ×(Pr)1/3
km
= 0.023 × 0.2 ×( v ρm )0.8 ×(Pr)1/3
Di

Taking logarithm in both side,

km
log(hi) = log0.023 0.2 ×( v ρm )0.8 ×(Pr)1/3+ 0.8log(v)…………………………..(2)
Di

It is the equation of a straight line in the form of y=mx+c with a slope of 0.8. The slope of the
graphs representing water side heat transfer coefficient (hi) versus velocity of water for 5, 10 and
15 psig is determined to be 0.74, 0.75 and 0.74 respectively which were quite concordant with
theoretical value of 0.8.

13
Besides it can be seen from the graphs that with the increase in velocity of water flow the water
side heat transfer coefficient increases. It is due to increased forced convection due to the
increase in fluid(water) velocity.

10000.00
Heat Transfer Co-efficient (hi)

1000.00
0.10 1.00
Velocity of Water (v)

Figure 5: Variation of Water Side Heat Transfer Coefficient with Velocity of Water
(Steam Pressure of 5 psig)

10000.00
Heat Transfer Co-efficient (hi)

1000.00
0.10 1.00
Velocity of Water (v)

14
 Figure 6: Variation of Water Side Heat Transfer Coefficient with Velocity of Water
(Steam Pressure of 10 psig)

10000.00
Heat Transfer Co-efficient (hi)

1000.00
0.10 1.00 10.00

Velocity of Water (v)

Figure 7: Variation of Water Side Heat Transfer Coefficient with Velocity of Water
(For Steam Pressure of 15 psig).

1 1 0.8
3) Wilson plot i.e. ( ) versus ( ¿ ¿
U v

The Wilson plot is drawn to calculation the dirt factor graphically. The overall thermal resistance
1
( ) may be expressed the sum of individual resistance, as such
UA

1
=Rc + Rw + Rd + R l ……………………(1)
UA

where, Rc, Rw, Rd, Rl are the condensate resistance, wall resistance, dirt factor and liquid side
resistance respectively.

For turbulent flow, liquid side resistance is a function of velocity such that

1
Rl = 0.8 …………………………….…………(2)
c2 v

Combining (1) and (2) we get,

15
 1 1
= Rc + Rw+ Rd+ 0.8 ………………………..(3)
UA c2 v

1
Experimental data for the experiment will abide by the equation (3) and when plotted as vs
U
0.8
1
( ) will give an intercept equal to (Rc + Rw+ Rd) in the y-axis. Whereas theoretically the tube is
v
0.8
1 1
considered to be clean where Rd=0. Theoretical data obtained when plotted as vs ( ) will
U v
give an intercept equal to (Rc + Rw) in the y-axis. Thus the difference between the y-axis
intercepts of the two graphs gives the value of dirt factor.

The theoretical line is found below the experimental line in our Wilson plot . The dirt factor is
found to be 3.1×10−4, 2.6 ×10−4 and 3.3×10−4 m2.K/W respectively for steam pressure of 5
psig, 10 psig and 15 psig respectively.

Figure 8: Wilson Plot (For Steam Pressure of 5 psig)

16
Figure 9: Wilson Plot (For Steam Pressure of 10 psig)

Figure 10: Wilson Plot (For Steam Pressure of 15 psig)

17
The results obtained from our experiment is quiet satisfactory. Despite the fact, we can be more
precautious in the future about the following things,

 The system must be given enough time to stable after every steam pressure
change.
 The flow meter may be changed with a rotameter which will eliminate the use of
stopwatch manually for determining water flow rate.
 Although the pipes were insulated, the insulating materials became too hot
during experiment. This proves that the insulating material were not enough.
More superior insulating materials needs to be used

REFERENCES

1. Cengel, Yunus., and Ghajar, Afshin J. Heat and mass transfer: fundamentals and applications.
McGraw-Hill Higher Education, 2014,Page-920,Table A-11.

2. Kern, Donald Q. Process heat transfer. Tata McGraw-Hill Education, 1997, Page-844, Table
11.

3. Holman, J. P., and Bhattacharyya, Souvik. Heat Transfer-In Si Units. Tata McGraw-Hill
Education, 2002,Page-597,Table-A2.

18
APPENDIX

Sample calculation

For observation no. 01 (5 psig Steam Pressure, No. 1 Observation):

Water inlet temperature, T1 = 28.00 oC

Water inlet temperature, T1 = 46.50 oC

(T 1+T 2) (28.00+ 46.50) o

Mean temperature of water, Tm = = C = 37.25 oC
2 2

Properties at mean temperature, Tm= 37.25oC

Density of water, ρm = 993.24 kg/m3 [1]

Viscosity of water, μm = 6.90996 x 10-4 kg/m.s [1]

Thermal conductivity of water, km = 0.6266W/m.oC [1]

Specific heat of water, Cp= 4178.00 J/kg.K [1]

19
Volume of water, L = 10 L

Water collection time, tw = 40.82 sec

10
Volumetric flow rate of water, Ww = L/ s =0.24 L/s
40.82

0.24 × 993.24
Mass flow rate of water, Mw = W w × ρm = ( ) kg/s = 0.24 kg/s
1000

Mass of condensate collected, Wc = 0.9 kg

Condensate collection time, tc = 120 s

Wc 0.9
Mass flow rate of condensate, MC = =( ) kg/s = 0.0075 kg/s
tc 120

Rate of heat taken by water, Qw = Mw × Cp× (T2-T1)

= 0.24 × 4178.00 × (46.50-28.00) J/s

= 18807.08 J/s

Heat of condensation of steam at 5 psig (19.7 psia), λs = 2199.47 kJ/kg

Rate of heat given by steam, Qc = Mc × λs

= (0.0075 × 2199.47) kJ/s

=16496.03 J/s

Mean rate of heat flow,

QW +QC 18807.08+16496.03
Qm = = J / s = 17651.55 J/s
2 2

Saturation temperature of steam at 5psig (19.7 psia), Ts = 108.39oC

20
Temperature difference at inlet,

ΔT1 = Ts - T1 = (108.39 – 28.00)oC = 80.39oC

Temperature difference at outlet,

ΔT2 = Ts - T2 = (108.39 – 46.5) oC = 61.89 oC

Log mean temperature difference,

ΔT 1 −ΔT 2
ΔT 1 80.39−61.89
ln 80.39
ΔT 2 ln
61.89
o
ΔTlm = = C = 70.47oC

For 1 in. nominal diameter & schedule 40 steel tube,

The outside surface per linear feet, Ao = 0.344 ft2/ft[2]

Inside diameter (ID) of the pipe, Di = 1.049 in. = 0.02665 m.[2]

Outside diameter (OD) of the pipe, Do = 1.32 in. = 0.033528 m.[2]

Tube length = 7 ft. 4 in. = 88 in. = 7.33 ft.

Outside area available for heat transfer, Ao = 0.344×7.33 ft2 = 23.54 x 10-2 m2.

Qm
Experimental overall heat transfer coefficient, UOE = ΔT lm . A0

17651.55 2 o
= −2 W/m . C
70.47 ×23.54 × 10

= 1059.86 W/m2.oC

Now,
0.24
Ww 1000
Velocity of water flow, v = = 2 m/s = 0.44 m/s
Ai 0.02665
3.1416 ×( )
4

21
 Di × ρ× v 0.02665 ×993.24 ×0.44
Reynolds number of water, Re = = −4 = 16823.75
μm 6.90996× 1 0

C P × μm 4178 ×6.909996 × 10−04

Prandtl no. of water, Pr = = = 4.61
km 0.6266

1
Nusselt number of water, Nu=0.023 × ℜ0.8 × Pr 3 = 91.96

Water side heat transfer coefficient for turbulent flow using Dittus-Boelter equation,
km
h = 0.023 × D i ×(Re)0.8 ×(Pr)1/3
i

0.6266
= 0.023× × (16823.75)0.8× (4.61)1/3
0.02665
= 2160.65 W/m2.oC

T s+T m 108.39+37.25
Wall temperature,Tw= = ℃=72.82 ℃
2 2

Film temperature, Tf = Ts-0.75 × (Ts-Tw)

= 108.39- 0.75× (108.39–72.82) oC

= 81.71oC

Properties of condensate at film temperature, Tf = 81.71oC

Density, ρf = 970.53 kg/m3[1]

Viscosity of condensate, μf = 3.47 ×10−4 kg/m.s[1]

Thermal conductivity of condensate, kf = 0.67 W/m.oC[1]

Steam side heat transfer coefficient using Nusselt equation for film type condensation,

22
 k 3 . ρ 2 . g . λS
f f 0. 25
0 . 725×[ ]
ho = D 0 (T S −T W )μ f

=0.725 ׿ W/m2.oC

= 7999.15 W/m2.oC

Carbon-steel metal’s thermal conductivity, kM = 43 W/m.oC [3]

Theoretical overall heat transfer coefficient,

UOT = ¿

= ¿ W/m2.oC

= 1256.18 W/m2.oC

1 1
Now, = =¿ 9.44 ×10−4 m2.oC/W
U OE 1059.86

1 1
= = 7.96065 ×10−4 m2.oC/W
U OT 1256.18

1 1
= 0.8
v
0.8 ¿ ¿ (s/m)

23