ABSTRACT

This experiment was conducted to evaluate and study the performance

of the shell and tube heat exchanger heat load and heat balance, LMTD,
overall heat transfer coefficient ,Reynolds shell side and tube side, heat
transfer coefficient and pressure drop at shell side and tube side. The
experiment will run in 2 with 3 sets each. Each 2 runs will be using different
nominal flow rates for CW and HW. We carried out for Run III and IV only. The
QC/QH that close to 1.00 will be chosen to use for U calculation. Every run
will be using different flow rate. From the result, the pressure drop depends
on the flow rate not the temperature. As we can see that the pressure drop
for Run III which used 10USGPM and 15USGPM was higher than pressure at
Run IV which used 10USGPM. From the calculation, we conclude that the
number of QC is decreasing from Run III to Run IV and same pattern goes to
QH and 0.5(QC+QH).Other than that, U is also decreasing from RUN III to Run
IV. The overall heat transfer coefficient, U, Reynolds number and flow rates
of hot water are also decreasing from Run III to Run IV.

INTRODUCTION
Shell-and-tube heat exchangers are commonly used in oil refineries
and other large-scale chemical processes. A heat exchanger is a device that
is used to transfer thermal energy between transfer thermal energy between
two or more fluids, between a solid surface and a fluid a fluid, or between
solid particulates and a fluid at different temperatures and in thermal contact
In this model, two separated fluids at different temperatures flow through the
heat exchanger: one through the tubes (tube side) and the other through the
shell around the tubes (shell side). Several design parameters and operating
conditions influence the optimal performance of a shell-and-tube heat
exchanger. The main purpose of this model is to show the basic principles for
setting up a heat exchanger model. It can also serve as a starting point for
more sophisticated applications, such as parameter studies or adding
additional effects like corrosion, thermal stress, and vibration.
The heat exchanger is made of structural steel. The participating fluids
are water flowing through the tube side and air flowing through the shell
side. The baffles introduce some cross-flow to the air and such increasing the
area of heat exchange. Another advantage is that baffles reduce vibration
due to the fluid motion.(Comsol,2013).

Figure 1: Geometry of shell and tube heat exchanger

The scope of shell and tube heat exchanger
Maximum pressure
Shell 300 bar (4500 psia)
Tube 1400 bar (20000 psia)
Temperature range
Maximum 600oC (1100oF) or even 650oC
Minimum -100oC (-150oF)
Fluids
Subject to materials
Available in a wide range of materials
Size per unit 100 - 10000 ft2 (10 - 1000 m2)
However shell and tube heat exchanger can be extended with special
designs and materials.
Heat Exchangers are classified according to

Transfer process
Number of fluids
Degree of surface contact
Design features
Flow arrangements
Heat transfer mechanisms

Shell and tube heat exchanger is the most common type of heat
exchanger in industrial applications.It contain a large number of tubes
(sometimes several hundred) packed in a shell with their axes parallel to that
of the shell. Heat transfer takes place as one fluid flows inside the tubes
while the other fluid flows outside the tubes through the shell. Shell-and-tube
heat exchangers are further classified according to the number of shell and
tube passes involved.(Cengel,2011).

Figure 2: Schematic shell and tube heat exchanger(open shell pass and one
tube pass).

Regenerative heat exchanger: Involve the alternate passage of the hot

and cold fluid streams through the same flow area.

Dynamic-type regenerator: Involve a rotating drum and continuous
flow of the hot and cold fluid through different portions of the drum so
that any portion of the drum passes periodically through the hot

stream, storing heat, and then through the cold stream, rejecting this

stored heat.
Condenser: One of the fluids is cooled and condenses as it flows

through the heat exchanger.

Boiler: One of the fluids absorbs heat and vaporizes.

OBJECTIVE

To evaluate and study the performance of shell and tube heat

exchanger at various operating condition.

To evaluate and study the heat balance, LMTD and overall heat
transfer coefficient.

To calculate Reynoldss number at the shell and tube heat

exchanger.

To measure and determine the shell and tube side pressure drop.

THEORY
In most heat exchangers, two fluids are exchanging their heat without
direct physical contact to avoid mixing. This is called indirect heat transfer.
Cooling water temperature in a hot area is normally above 25 degrees
centigrade, and it depends on the atmospheric and climate condition. To
reach the range of 1 to 5 degrees centigrade, we need to use chilled water,
which is already cooled by a refrigerant. For heating purposes, the
mechanism is similar to the cooling. We can use hot intermediate fluid such
as hot water or steam and even other hot process streams.

To proceed on the heat exchanger theory we need to know that the meaning
of the following terminologies:
The overall heat transfer rate in a heat exchanger
The overall heat transfer coefficient can be used to calculate the total
heat transfer through a wall or heat exchanger construction. The overall heat
transfer coefficient depends on the fluids and their properties on both sides
of the wall, and the properties of the wall and the transmission surface.

Q = U A T

= Overall heat transfer coefficient

= Area of the tube

= Logarithmic mean temperature difference

Heat load and heat balance

This part of the calculation is to use the data in Table to check the heat
load

and

and to select the set of values where

Hot water flow rate (

)
=

Cold water flow rate (

)
=

where:

is closest to

= Heat load for hot water flow rate

= Heat load for cold water flow rate
Hot water mass flow rate
Cold water mass flow rate
Hot water inlet temperature
Hot water outlet temperature
Cold water inlet temperature
Cold water outlet temperature

Log mean temperature difference (LMTD)

The corrected LMTD= FT x LMTD calculated above

Overall heat transfer coefficient,

Overall heat transfer coefficient at which equivalent to
by using equation

can be calculated

Where:
Heat rate with respect to the flow rate of water
Theoretically Q above is equal to

or

or

If there any error in temperature collected, it is recommended to calculate

value based on equation of
value.

Reynolds Number
Shell-side Re(s) for CW

that will give an average

Where:
Pitch = 0.81inch
Tube outside diameter, inch
Viscosity, taken at average fluid temperature in the shell, lbmft-1hr-1

(lbmft-2hr-1)
Flow rate in (lbmhr-1)
Tube-side Re (t) for HW

Where:
Viscosity, taken at average fluid temperature in the tube, lbmft-1hr-1

Heat Transfer Coefficient

Both values of internal heat transfer coefficient,

coefficient,

and outside heat transfer

obtained from equation below:

And

Where:
Thermal conductivity at mean temperature with respect to fluid
position
Fluid viscosity at mean temperature with respect to fluid position
Fluid viscosity for different value of hot and cold water stream
Energy being transfer in the system

Therefore, the dirt factor,

value :

Where:

and

Clean overall heat transfer coefficient from both individual inside

outside fluids

Overall heat transfer coefficient obtained from calculation in part 1

From the equation before, UC value is calculated from heat transfer
coefficients, the Reynolds number (i.e flow rates), the flowing fluids
properties and the Heat Exchanger diameters.
value however is determined from actual heat transfer experiments at
the Heat Exchanger diameters.
It is the dirty or design heat transfer coefficient. Fouling phenomenon would
reduce
value. Fouling may get worse with operation, resulting in reduced
heat transfer and increasing pressure drop (and loss of flow).

Pressure drop
This part would determine the following:
: The measured tube-inside pressure drop DP (tube) which will be
corrected and is expected to be more than calculated tube-side pressure
drop.
: The measured shell-inside pressure drop DP (shell) which will be
corrected and is expected to be more than calculated tube-side pressure
drop.

Pressure drop measurement

The shell and tube-side pressure drop (DP) are measured using the
differential pressure transmitter (DPT) and then indicated digitally at the
panel DP (DPI*). A selector switch with a set of 5 solenoid valves allows both
the shell and tube-sides pressure drop i.e. DP (shell), DP (tube), to be
measured one at a time.

APPARATUS

Summary List of Instrumentation

Field-Mount
FT (H)
USGPM

Flow Transmitter for HW. Vortex flow meter, 0-30

FT (C)

Flow Transmitter for CW. Magnetic flow meter, 0-30 USGPM.

DPT
Pressure

Differential Pressure Transmitter for Shell/Tube side

drop, 0-5000 mm H2O.

TE1 to TE5 :

Temperature Element Resistance Temperature Detector

(RTD), for t1, t2, T1, T2 TIC5 respectively,

0-1000C.
PG-H, PG-C :

Pressure gauges, 0-60 psig.

TG2

Temperature gauge, 0-1000C.

TSV3A, TSV3B

Temperature Solenoid Valve.

FI (H), FI (C)
USPGM

Flow Indicator for HW, CW. Digital display, 0-30

TI1, TI2, TI4 :

and

Temperature Indicator for TE1, TE2, TE4, displaying t1, t2

T2 respectively. Digital display, 0-1000C

TI3 (T1)/TIC3
i.e. T1.

TIC5

Temperature Indicator with ON/OFF control for TE5.

Digital display, 0-1000C

DPI
of

Differential Pressure Indicator for DP (Shell) and DP (Tube)

Heat Exchanger. Digital display, 0-5000 mm H2O

Flow, Temperature, Deferential Pressure Recorder, 12-

Panel-Mount

Temperature Indicator with ON/OFF control for TE3

Digital display, 0-1000C

Portable
FTDPR

Channels, paperless and can be connected to PC-Data Acquisition

System

PROCEDURE
Preparation procedures
Start the following preparation procedures step-by-step.
i)

Tanks T1 and T2 was filled with water to their maximum level define by their
overflow drain pipes D.

ii) At tank T1, the discharge valve (HV) was shut fully, but open fully its by-pass
valve (BVH). The HW pump PH was start for the water to recirculate around
its tank T1, via only BVH. The suction valve of pump PH must remained
open at all times.
The heaters at the front of the panel was switch on and the water was
allowed in tank T1 to be heated to its maximum temperature 70

/ 158

(see T1C5), which will took about 20 minutes. Whilst waiting, proceed

to (iii) below. The heaters in tank T1 was automatically switch off by the
on/off temperature controller T1C5 when the heated water temperature
exceeds its preset High Limit (say 70 ), and when the temperature drops
below switch them on again, say of its preset High Limit (i.e. below 69.5
).

iii) CW System : Heat Exchanger Shell side

Meanwhile got familiar with the equipment, instrumentation, piping system

and the various manual valves. The following preliminary procedures are
recommended for farmilarization.
a) All the CW pumps (PC1, PC2) by pass valves (BVC1, BVC2) and discharge
valves (CV1, CV2) was checked that were opened. The suction valves of
all the pumps (PC1, PC2 and PH) was noted that must remained opened
at all times.
b) The external water supply to tank T2 was checked that always available
but was automatically shut by the mechanical float-level valve at high
level in tank T2. The water availability was tested by pushing down the
float-water must flow into tank T2 via the float-level valve to confirm
water availability.
c) Make sure the CW pumps PC1 and PC2 were off. The HW pump PH was
noted that still recirculating HW around its tank T1 via its by-pass valve
(BVH), but its discharge valve (HV) was still fully shut.
d) Only one CW pump was switch on, say PC1 whose suction was from tank
T2. Its by-pass valve BVC1 was still fully opened. PC2 was did not
operated. CV2 was shut fully. The CW recirculation was noted from PC1
back into tank T2 via mainly its by-pass valve BVC1 and the Heater
Exchanger returned solenoid valve TSV3A.
e) The by-pass valve ( BVC1) was parctise manipulated to set various
flowrates of CW into the Heat Exchanger from PC1 as follows:

Remain fully opened the manual discharge valve CV1.

With BVC1 was fully opened, the CW flowrate {FC at FI(C*)} was
noted,drop the pressure (PG-C) and shell-side (at DPI*). To read DP
(shell), the signal to DPI* was selected used the DP Selector Switch
provided at the panel, to the DP (shell) position and wait till the
reading at DPI* was almost steady.

Manually adjusted BVC1 until FC at FI(C*) reads almost 10 USGPM. A

DP (shell) and PG-C was noted.

The by-passvalve ( BVC1) was shut fully and the increase in FC, PG-C
and (shell) was noted. The CW temperatures was noted at the Heat
Exchanger inlet (T1 at TI3*) oulet (T2 at TI4*). The Heat Exchanger
pressure drop increases with flowrates was noted.

f) Pump PC2 was switch on whose suction was from tank T2. Opened fully
its manual discharge valve CV2 and by-pass valve (BVC2). The CW
flowrate {FC at FI(C*)} was note, pressure (PG-C) and shell-side
pressured drop (at DPI*).

Gradually shut only BVC2 until the CW flowrate FC is about 200

USGPM. Fc, PG-C and DP(shell) was noted which increased with the
flowrate FC.

g) BVC2 was opened fully but CV2 was shut fully so that pump PC2 now
operates only as be mixing pump for tank T2. The drop in FC, PG-C and
DP(shell)was noted. Only pump PC1 was now pumped through the Heat
Exchanger. Shut BVC1 fully maximum flow from PC1 through the Heat
Exchanger. Both the CW pumps PC2 and PC1 was swith off. The DP
Selector Switch was switch to the equalising (vertical or 0) position.
iv)

Hw system : Heat Exchanger Tube side

a) TIC5 was noted to checked if the water temperature in tank T1 was
about 70

(158

before proceeding to the next procedure

(b). The discharge valve (HW) was noted, the HW pump PH was still
shut but its by-pass valve (BVH) was fully opened.
b) The by-pass(BVH) was gradually shut fully and simultaneously opened
its discharge valve (HV) sully so that the maximum HW flows into the
Heat Exchanger and return into tank T1. The HW flowrate {FH at
FI(H*)} was read, pressure (PG-H) and Tube-side pressure drop (at
DPI*). Select the DP signal to DPI* to read used the DP Selector Switch
provided at the panel, to the DP (Tube) position. Wait till the DP (Tube)

reading at DPI* almost steady to took the reading.

In tank T1, the temperature of HW will drop due to heat being transferred to
the metal body of the Heat Exchanger,even if there was no CW flow in the
Heat Exchanger. The HW temperature at the Heat Exchanger inlet (t 1 at
T11*) and oulet (t2 at T12*)
c) The HW pump PH was stopped and the drop in FH, PG-H and DP
(Tube) ws noted. The DP Selector Switch to the equalizing (vertical
o ) position was switched. The heat from HW was noted and now
stored in the Heat Exchanger tubes. The heaters was switch off.
d) Proceed to (C1) PLANNING THE EXPERIMENT.
(C1) Planning The Experiment
Refer to table 1 and plan out the experiment strategy as follows :
i) RUN1
a) Run 1 was done at the following recommended nominl flowrates. It was
not necessary to operated at exactly the recommended nominal flowrates
below. Adeviation of

was acceptable for tested purposes.

CW, FC :110 USGPM

HW, FH : 25 USGPM

b) Please refered to table 1, Three (3) sets of readings were taken for every
RUN.

Each set of temperature readings consists of four readings to be taken

simultaneously :
CW Temperature inlet T1 at TI3* and outlet T2 at TI4*,
HW temperatures inlet T1 at TI1* and oulet T2 at TI2*

Each set of flowrate readings consists of two readings:

CW flowrate {FC at FI(C*)}
HW flowrate {FH at FI(H*)}

Each set of pressure drop readings consists of two readings :

DP (shell) at DPI*, with the DP Selector Switch at the DP (shell)

position.
DP (Tube) at DPI*, with the DP Selector Switch at the DP (Tube)

position.

Each set of Heat Exchanger inlet gauge pressure readings consists of

two readings :
PG-C of CW pipeline, inlet to the Shell side of the Heat Exchanger.
PG-H of HW at the HW pipeline, inlet to the Tube side of the Heat

Exchanger.
c) The HW temperature in tank T1 drops (note TIC5) was noted when the
heater input was inadequate to meet with the heat (QC) removed by CW.
Hence the second and third sets of temperature readings may be taken at
decreasing heat load, but the water temperature at tank T1 must be at
least 60 .
d) Concentrated on taking the three (3) sets of temperature, flowrate and
pressure drop readings. The pressure drop readings DP( shell) and
DP(Tube) were taken at the panel-mount DPI*, used the DP signal Selector
Switch provided. The pressure drop depends on the flowrate and not on
the temperature was noted.
e) The above procedure for other RUNS (II, III, etc) was repeated at the
following CW and HW recommended nominal flowrates. A deviation of

15% was acceptable. A summary list of the recommended nominal

flowrates.
RUN
CW, FC
III
10USGPM
IV
10USGPM
(C2 ) Experimental Procedures

HW, FH
15 USGPM
10USGPM

With a good overview of the experiment plan detailed in C1, proceed with
RUN I as follows:
i)

All the pump suction valves (for PH, PC1, PC2) were checked and fully

opened all the time.

Opened BVC2 fully but shut CV2 fully so chat that PC2 shall operated as
a back-mixing pump for r tank T2 in the next experiment. CV1 BVC1 was
opened fully. To pump CW into the Heat Exchanger in

the next

experiment used PC1 shall. Did not switch on any CW pumps (PC1, PC2)
yet.

Shut HV fully but opened BVH fully.

To circulate around tank T1 via only BVH was started pump PH for HW.

The heaters was started and noted TIC5. When the HW in tank T1 was
almost 70 /158 (see TIC5), opened HV fully. The HW flowrate
was quickly adjusted to abouat 25 USGPM by regulating its by-pass
valve BVH.

CW pumps PC1 and PC2 was switched on. The CW flowrate was quickly
adjusted to about 10 USGPM by regulating the by-pass valve BVC1.

The DP Selector Switch to the DP (Shell) position was switched.

ii)
a) First set of temperature and flowrate readings was took:
CW: Temperature- inlet/oulet, TI3* (T1), TI4* (T2):
Flowrate FC at FI(C*).
HW: Temperature- inlet/oulet, TI1*(t1), Ti2* (t2):
Flowrate FH at FI(H*)
The CW inlet temperature (T1) was increased gradually was noted. The CW
oulet temperature (T2) varies together with the HW inlet/oulet tenperature
t1/t2. All the temperature and flowrate readings was important and be taken
almost simultaneously.
Readings appropriately in table 1 was recorded:

The respective inlet pressure and pressure drop of the CW and HW flow
streams was recorded. For the pressure drop readings, DP (Shell), DP
(Tube) at the panel-mount DPI*, used the DP signal Selector Switch

appropriateky as explained below.

CW: PG-C, DPI* for DP(Shell) with the DP Selector Switch at the DP
(Shell) position.
HW: PG-H , DPI* for DP (Tube) with the DP Selector Switch at the DP
(Tube) position.
To take the DP readings at DPI*, wait till they were fairly steady. Then
took the DP reading at its highest reading (i.e. peak reading) just when
it starts to decrease.
`b)Continued and took the second and third sets of the above readings
for RUN I consecutively.

When all the temperatures were fairly steady,

the last Set of temperature readings should be taken.

iii)

RUN i was completed, with three sets of the above readings

All the CW pumps PC1 and PC2 was stopped.

Keep the Heaters on for the next RUN

With the HW pump PH still running, shut fully the discharge valve HV
but opened fully the by-pass valve BVH.

The DO Selector Switch was switched to equalizing (vertical or 0)

position.

v) Analyst the data by computing the QC and QH values for each of the three(3)
sets of readings for the previous RUN I whilst waited for the HW in tank T1
to be heated to about 70 /158

(see TIC5) for RUN II as follows:

a) For each set of readings in RUN I, the heat load QC and QH was
calculated for the CW and the HW as per the formula in section (E)
calculation.
b) The three (3)b calculated values of QC and QH for RUN I was
compared. Select the set of readings where QC was closest to QH and
noted them down in table 1 and table 2, as the selected QC and QH
for RUN I. At the same time, noted down their corresponding

temperatures, flowrates and pressure drops as the selected datas for

RUN I. The other two sets of data not selected can be rejected as they
were of no further used.
c) The above selected set od data i.e. QC, QH, temperatures, flowrates
and pressure drops for RUN I shall be used to compute the LMTD, the
overall heat transfer coefficient, Reynolds numbers, individual heat
transfer coefficient and the pressure drop, for RUN I.
d) Run IV,V at different recommended nominal flowrates of CW(i.e. FC)
and HW(i.e. FH) was repeated,used the following procedures check
list:

To continued with the next RUN

The HW pump PH was running with BHV fully opened but HV
fully shut was checked.

With the heaters on, the HW in tank T1 almost 70 /158

(see TIC5) was heated

Opened HV fully. The HW flowrate was adjusted until FH at FI

(H*) was almost at the recommended nominal flowrate for the
RUN. This was done by regulating the by-pass valve BVH with
HV fully opened. (However, if the flowrate was still too high
even when its by-pass valve was fully opened, gradually shut its
discharge valve, HV, to got the required HW flowrate)

The CW pumps PC1, PC2 with CV1/BVC1/BVC2 was started fully

opened but CV2 fully shut. Fc at FI(C*) as noted. Fc was
adjusted to the recommended nominal flowrates for the RUN by
regulating the by-pass valve BVC1 with CV1 fully opened.
(However, If the CW flowrate (FC) from PC1 was still inadequate
even when its by-pass valve BVC1 was fully shut, used the
second CW pump (PC2) by gradually opening CV2 and
simultaneouslt shutting BVC2 to got the required cw flowrate)

 The DP Selector Switch to the DP (Shell) position was switched

The various readings for the RUN was took. Refer to table 1 of
the apptopriate RUN.

To end a RUN after got 3 set of readings

All the CW pumps PC1, PC2 was stopped.
The DP Selector Switch to the equalising (vertival or o) position
was switched.
The HW pump PH and the heaters still on, shut fully HV but
opened BVH fully.

(C3) Plant Shut Down

I)

The heaters was switched off

II)

Checked all the pumps (PH, PC1, PC2) were switched off

III)

The DP Selector Switch to the equalising (vertical 0 ) position was

switched

IV)

The main power supply was switched off to the plant at the front of
the panel/cubical. All the pumps suction valves, discharge valves
(HV, CV1, CV2) and by-pass valves (BVH, BVC1, BVC2) was opened

RESULT
Table 1 : experimental data for RUN III
RUN III
Nominal Flow,
USGPM
Actual Flow, USGPM

SET 1
CW
FC: 10

FC: 9.8

HW
FH: 15

FH: 15.3

SET 2
CW

Pressure, psig, Inlet DP: 597

(SHELL)

PG-H: 4.7

SET 3
CW

HW

15

10

15

15.3

9.9

15.2

4.5

2.5

4.5

10

Temp, C, Inlet
PG-C: 2.5

HW

9.9

DP:1454(TU 2.5
BE)
621

* Temp change, C

23.7

* Average Temp, C 40.45

13.2

18.8

11.8

16.1

9.9

59.6

37.7

54.1

36.35

50.55

QC/QH

1.168

1.122

1.288

Select QC/QH
nearest to 1.0

SELECTED

NOT SELECTED

NOT SELECTED

Selected set,
194429.45

Table 2: experimental data for RUN IV

SET 1
CW
Nominal Flow,USGPMFC: 10
RUN IV

HW
FH: 10

Actual Flow, USGPM

Temp, C, Inlet

FC: 9.8

Pressure, psig, Inlet DP: 605

(SHELL)

HW

SET 3
CW

HW

10

10

10

10

9.8

10.4

9.8

10.4

2.0

2.5

2.0

FH: 10.5

Temp, C, Outlet
PG-C: 2.5

SET 2
CW

PG-H: 2.0
2.5
DP:
564(TUBE) 620

* Temp change, C

21.1

* Average Temp, C 39.85

16.1

16.6

14.1

15.2

13.0

58.75

37.7

54.15

37.00

52.3

QC/QH

1.22

1.109

1.101

Select QC/QH
nearest to 1.0

NOT SELECTED

NOT SELECTED

Selected set,

SELECTED
128140.53

Table 3 : calculated value for heat load, LMTD and U

RUN

III
IV

QC
(BTU/hr)

QH
(BTU/hr)

0.5(QC+
QH)
(BTU/hr)

209472.9
7
134345.5
3

179385.9
2
121935.5
3

194429.4
5
128140.5
3

U
LMTD*FT
(F)

( hr BTU
. ft . )
2

20.14

504.81

25.50

332.70

Table 4: calculated Reynolds number

Actual Flow
(USGPM)
FC: 9.8
FH: 15.3
FC: 9.8
FH: 10.4

RUN
III
IV

Re (s)

Re (t)

389.31

12833.12

364.46

7753.94

Table 5: Calculated Heat Transfer Coefficient and Dirt Factor

RUN

ho

hi

hio

Uc

Ud

Rd

BTU
BTU
BTU
BTU
( hr BTU
)
(
)
(
)
(
)
(
. ft .
hr . ft .
hr . ft .
hr . ft .
hr . ft . ) (x10 )
2

III
IV

1598.82
1620.18

721.68
604.95

571.57
479.12

421.05
263.63

504.81
332.70

-3

3.94
0.664

Table 6: Calculated Pressure Drop

RUN
III
IV

Pressure Drop
Shell-side (mmH2O)
Calcula Measur Correct
ted
ed
ed
4937.73 560
65.05
4484.88 564
69.05

Tube-side (mmH2O)
Calcula Measur Correct
ted
ed
ed
89.891
1093
353.72
18.79
563.32
191.88

CALCULATION
Sample calculation
RUN III, Set 1
Heat Load and Heat Balance
FC= 9.8 USPGM
m3/Hr

FC= 9.8 USGPM x

4.4 USGPM

1000 Kg 2.20462 Ibm

m3

FC= 4910.29 Ibm/hr

CP= 1 Btu/Ibm oF
QC= FC CP (T2-T1)
Convertion unit of temp.
T2 = 44.6 oC = 44.6(1.8) + 32 = 112.28 oF
T1 = 29.4 oC = 29.4(1.8) + 32 = 84.92 oF

kg

= 4910.29 Ibm/hr x 1 Btu/Ibm oF x (112.28 84.92 oF

= 209472.97Btu/hr

FH = 15.3 USPGM
FH = 15.3 USGPM

m3/Hr

1000 Kg 2.20462 Ibm

4.4 USGPM

m3

kg

FH = 7666.065Ibm/hr
CP= 1 Btu/Ibm oF
QH= FH X CP X (t1 - t2)

Conversion unit of temp.

t2 = 45.8 oC = 45.8(1.8) + 32 = 114.44 oF
t1 = 58.8oC = 58.8(1.8) + 32 = 137.84 oF
=7666.065 Ibm/hr x 1 Btu/Ibm oF x (137.84 114.44) oF
= 179385.92Btu/hr
Ratio QC/QH =

209472.97
179385.92

= 1.168

Calculations above were repeated for each set in RUN IV. The set which
gives the ratio of QC/QH nearest to 1 is then used for the next part of the
calculation for each respective RUN.

LMTD (RUN III, Set 1)

( 137.84114.44 )(112.2884.92)
( 137.84114.44 )
ln
(112.2884.92)

LMTD =

= 25.33

Correction factor, FT is obtained from figure 18 (appendices) based on the

value of R and S, where FT = 0.795

LMTD (true)= 0.795 x 25.33

= 20.14

Overall Heat Transfer Coefficient, U (RUN III, Set 1)

The total heat transfer area of the Heat Exchanger, A = 31.5 ft2
Q = 0.5(QC+QH)
Q = 0.5 (209472.97 + 179385.92)
Q = 194429.45(BTU/hr)
U

BTU
1
1
=194429.45 (
x
x
)
( hr BTU
)
hr
. ft .
31.5 ( ft ) 12.2271

504.81

BTU
hr . ft 2 .

All calculations involving LMTD and U were repeated again for the selected
set on RUN IV. The results of calculation are tabulated in table .

8.2 Reynolds Number

Shell side Re(s) for CW (RUN III, Set 1)
( s )=De .

4
d e=

Gs

Pt
1 d
x 0.87 P t o
2
2 4
do
2

Given,

do

)
= 0.625 ins

Pt

= 0.8125 ins

Ws

= 4910.29 lbm/hr

As

= 0.029 ft2

= 1.584 lbm/ft.hr

Gs

= 4910.29 /0.029 = 169320.34 lbm/hr.ft2

de

= 0.537838 ins x 0.08333 = 0.0443 ft

De

= 0.0443/12 = 0.003642ft

Re (s)

= 0.003642 x(169320.34 / 1.584) = 389.31

Tube side Re (t) for HW (RUN III, Set 1)

( t )=D .

Gt

Given,

= 0.04125 ft

Wt

= 7666.065 lbm/hr

At

= 0.02139

= 1.152 lbm/ft.hr

Gt

= 7666.065/0.02139 = 358394.81 lbm/hr.ft2

Re(t) = 0.04125 x (358394.81 / 1.152) = 12833.12

8.3 Heat Transfer Coefficient, hi and ho, Uc, Ud and Rd

Calculation of ho for shell-side (CW) (RUN III, Set 1)
Given,

De

= 0.003733 ft

Cp

= 1.001 btu/lbm..F

= 0.36462 btu/hr.ft2. .F/ft (at Tavg = 40.45C)

= 1.584 lbm/ft.hr

Twall

=( 40.45+59.6)OC/2=50.030C

wall

= 2.412lbm/ft.hr (at Twall)

From figure 28(appendices), when Re (s) = 389.31, jh = 9.85

9.85

ho

ho (0.003733) (1.001 x 1.584)1/ 3 1.5840.14

0.36462
0.364621 /3
2.4120.14

= 1598.82

( hr BTU
. ft . )
2

Calculation of hi for tube-side (HW) (RUN III, Set 1)

Given,

= 0.04125 ft

Cp

= 1.001 btu/lbm..F

= 0.37871 btu/hr.ft2. .F/ft (at Tavg = 59.6 C)

= 1.152 lbm/ft.hr

From figure 28(appendices), when Re (t) = 12833.12, jh = 61

61 =

hi 0.04125 (1.001 x 1.152)1 /3 1.1520.14

0.3734
0.378711/ 3
2.4120.14

hi = 721.68

( hr BTU
. ft . )
2

Calculation of Clean Overall Heat Transfer Coefficient, Uc (RUN III, Set 1)

hio =721.68 x

U c=

hio x ho
h io + ho

0.495
0.625

= 571.57

= 421.05

BTU
hr . ft 2 .

BTU
hr . ft 2 .

Calculation of Dirt Factor, Rd (RUN III, Set 1)

= 504.81

BTU
hr . ft 2 .

Uc

= 421.05

BTU
hr . ft 2 .

Rd

Ud

504.81421.05
504.81 X 421.05

= 3.94x 10-4

8.4 Pressure Drop

Conversio
n:

1 psi = 2.3088ft = 27.72 ins = 703.72 mmH2O at 60F

(SG=1.0)

Shell side pressure drop (RUN III, Set 1)

f x Gs2 x D s(N + 1)
2 x g x x D e x s

Ps =
Given,

Ps =

Ds

= ID = 6.065ins = 0.50541 ft

= 23

= 4.17 x 108 ft/hr2

= 62.0348 lbm/ft3 (at Tavg = 40.45C)

De

= 0.003733 ft

Gs

= 169320.34 lbm/ft2.hr

SG

= 0.9931 (at Tavg = 40.45C)

= 1.01167

= 0.0052 (at Re(s) = 389.31)

0.0052 x 169320.342 x 0.50541(23+1)

2 x ( 4.17 x 10 8) x 62.0348 x 0.003733 x 1.01167

= 9.2550 psi

Since SG = 0.9931,
1psi = 703.72 x 0.9931 = 698.86 mmH2O
Ps = 9.2550 psi x 698.86 mmH2O / 1 psi = 4937.73 mmH2O

Correction to the measured pressure drop for Shell side, CW (RUN III, Set 1)
Pressure drop read at 560 mmH2O and flow rate CW of 9.8 USGPM,
Calculated piping pressure drop DP(s) = 494.95 mmH2O

P (corrected) = 560-494.95 = 65.05mmH2O

Tube side pressure drop, HW (RUN III, Set 1)

Pt =
Given,

f x Gt 2 x L x n
2 x g x x D x t
D

= 0.04125 ft

L x n = 12

Pt =

= 61.392 lbm/ft3 (at Tavg = 59.6C)

Gt

= 358394.81 lbm/hr.ft2

SG

= 0.98671(at Tavg = 59.6C)

= 0.9893

= 0.00012 (at Re(t) = 12833.12)

0.00012 x 358394.812 x 12
2 x (4.17 x 108) x 61.392 x 0.04125 x 0.9893

= 0.1295 psi

Since SG = 0.98671,
1psi = 703.72 x 0.9871 = 694.14 mmH2O

Pt = 0.1295 psi x 694.14 mmH2O / 1 psi = 89.891 mmH2O

Pr =

V
2 g'

V2
2g'

( )( 62.5
144 ) = 0.02 (at G = 358394.81 from figure 27 in appendices)

Where

Pr =

( )( )( 62.5
144 )
4n
SG

4 (2)
( 0.98671
)x

0.02 = 0.1622psi x 694.14 mmH2O / 1 psi = 112.56

mmH2O

Pt = P' t + P r

= 89.891+ 112.56= 202.45mmH2O

Correction to the measured pressure drop for Tube side, HW (RUN III, Set 1)
Pressure drop read at 1093 mmH2O and flow rate CW of 15.3USGPM,
Calculated piping pressure drop, DP (t) = 739.28 mmH2O

P (corrected) = 1093-739.28 = 353.72 mmH2O

DISCUSSION
The objective of the experiment is to evaluate and study the
performance of shell and tube heat exchanger at various operating condition.
Besides that, evaluate and study the heat balance, LMTD and overall heat
transfer coefficient. We need also calculate Reynoldss number at the shell
and tube heat exchanger and measure and determine the shell and tube side
pressure drop. During the experiment, we carried out Run III and Run IV
experiment. Every run consist of three set of data which need to be
considered.
Firstly, set up equipment according to the variable we need to
investigate which are pressure and temperature. The ideal temperature for
this heat exchanger is between 50

C and 70

C. So that, experiment run

when the ideal temperature is achieve. For run III the flow rate is set to the
10 USGPM

cold water (CW) and 15 USGPM for hot water (HW).The

experiment was run until the value of flow rate was stable. Then, all the data
was record for set 1.The experiment were repeated three times to get best
result. The calculation was made from data recorded to identify which set of
Run III have better result.
The heat load was calculated for all sets of data. The ratio of Q C/QH
which nearest to 1.0 is selected to continue the calculation. Then, for RUN III,
set 1 is selected. The QC is 209472.97 Btu/hr ,QH is 179385.92 Btu/hr and
0.5(QC+QH) is 194429.45 Btu/hr. Next, the corrected LMTD was 20.14 0F

while the overall heat transfer coefficient is 504.81

( hr BTU
. ft . )
2

. The

Reynolds number for shell is 389.31 and for tube is 12833.12.Other than

that, for part III value

( hr BTU
. ft . )
2

( hr BTU
. ft . )
2

and 571.57

( hr BTU
. ft . )

ho, hi and hi0 are 1598.2

( hr BTU
. ft . )

and UD is 504.8

, 721.68

respectively. For UC the value is 421.05

( hr BTU
. ft . ) .The value of R is 3.94 x x10
2

-3

.Next,

for the pressure drop at shell-side the calculated value, measured and
corrected are 4973.73 mmH2O,560 mmH2O and 65.05 mmH2O respectively.
For the pressure drop at tube-side the calculated value, measured and
corrected are 89.891 mmH2O,1093 mmH2O and 353.72mmH2O respectively.

For RUN IV, the flow rate was set up to 10 USGPM for both cold water
(CW) and hot water (HW).The instrument is run for a while until the ideal
temperature is achieved. For RUN IV, set 3 is selected. This is because the
ratio of QC/QH is nearest to 1.0 which is 1.101. The QC is 134345.53 Btu/hr ,QH
is 121935.53 Btu/hr and 0.5(QC+QH) is 128140.53 Btu/hr. Next, the
corrected LMTD was 25.5 0F while the overall heat transfer coefficient is

332.7

BTU
hr . ft 2 .

) . The Reynolds number for shell is 364.46 and for tube is

7753.94.Other than that, for part III the h o, hi and hi0 are 1620.18

604.95

( hr BTU
. ft . )
2

and 479.12

( hrBTU
. ft . )
2

BTU
hr . ft 2 .

),

respectively. For UC the value is

263.63

( hr BTU
. ft . )
2

and UD is 332.70

( hr BTU
. ft . )
2

. The value of RD is 0.6604 x

x10-3 .Next, for the pressure drop at shell-side the calculated value,
measured and corrected are 4484.88mmH 2O,564mmH2O and 69.05 mmH2O
respectively. For the pressure drop at tube-side the calculated value,
measured and corrected are 18.79mmH 2O,563.32mmH2O and 191.88mmH2O
respectively.
From the result above, the pressure drop depends on the flow rate not
the temperature. As we can see that the pressure drop for Run III which used
10USGPM and 15USGPM was higher than pressure at Run IV which used
10USGPM. From the calculation, we conclude that the number of QC is
decreasing from Run III to Run IV and same pattern goes to QH and
0.5(QC+QH).Other than that,U is also decreasing from RUN III to Run IV. The
overall heat transfer coefficient, U, Reynolds number and flow rates of hot
water are also decreasing from Run III to Run IV.

CONCLUSION
The objective is achieved for Run III and Run IV. Based on evaluate and
study the performance of shell and tube heat exchanger at various operating
condition was determined. Besides that, the heat balance, LMTD and overall
heat transfer coefficient also determined. The Reynoldss number at the shell

and tube heat exchanger was identified. Moreover, the shell and tube side
pressure drop also determined. From the result , the pressure drop depends
on the flow rate not the temperature. As we can see that the pressure drop
for Run III which used 10USGPM and 15USGPM was higher than pressure at
Run IV which used 10USGPM. From the calculation, we conclude that the
number of QC is decreasing from Run III to Run IV and same pattern goes to
QH and 0.5(QC+QH).Other than that,U is also decreasing from RUN III to Run
IV. The overall heat transfer coefficient, U, Reynolds number and flow rates
of hot water are also decreasing from Run III to Run IV.

RECOMMENDATION

The water to the tube side should be the first and last flow rate to be
turned on.

The steam should be turned on only after the water is flowing through
the tube side
and the water should be turned on only after the steam has been
turned on.

Fully drain system after each use of water on tube side and steam
condensate on
shell side in order to avoid corrosion build-up during down-times.

The eye position should be perpendicular to the meniscus and the

scale.
Avoid any leakage of the instrument, the instrument should be working
properly
Avoid direct contact with water because it is hot

REFERENCE

 Comsol.(2013).Shell and tube heat exchanger. Retrieved from:

https://www.comsol.com/model/download/177045/models.heat.shell_an
d_tube_heat_exchanger.pdf
Yunus A. Cengel, Afshin J. Ghajar.(2011). Heat and Mass Transfer:
Fundamentals & Applications Fourth Edition McGraw-Hill.
http://www.inspection-for-industry.com/heat-exchangertheory.html#sthash.z1rLpGBV.dpuf
http://www.engineeringtoolbox.com/overall-heat-transfer-coefficientsd_284.html
http://iitkgp.vlab.co.in/?sub=35&brch=107&sim=1174&cnt=1

APPENDIX

Appendix Data: Approximated data for water

TEMP
C

SG
(1.0 at
60F)

71.1
65

0.985

60
54.5

0.9872

48.9

0.9901

DENSITY
lbm/ft3

DENSITY
lbm/USG

61.00

8.156

61.30

8.182

61.38

8.207
8.227

61.71

8.253

61.94

8.289

62.06

8.296

48
40
35

0.995

VISCOSITY
lbm/ft. sec

2.6947 x
10-4
2.9272 x
10-4
3.1503 x
10-4
3.430 x 104
3.7565 x
10-4
3.8223 x
10-4
4.4083 x
10-4
4.8572 x
10-4

HEAT
CAPACI
TY
BTU/lb
m. F

THERMAL
CONDUCTIV
ITY
BTU/hr.ft2.
F/ft
0.3840

1.00

0.3830
0.3790

0.3710

0.999

0.3605