Last Rev.

: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 1

Grading Sheet
~~~~~~~~~~~~~~
MIME 3470Thermal Science Laboratory
~~~~~~~~~~~~~~
Laboratory 14
~~~~~~~~~~~~~~

SHELL-AND-TUBE HEAT EXCHANGER

~~~~~~~~~~~~~~

Students Names / Section

POINTS SCORE TOTAL
APPEARANCE, ORGANIZATION, ENGLISH/GRAMMAR 5
ORDERED DATA, CALCULATIONS & RESULTS
ORDERED DATA 5
CALCULATE HOT & COLD AVERAGED MEAN TEMPS, Tm 5
INTERPOLATED PHYSICAL DATA AT APPROPRIATE TEMPS 5
CALCULATE HOT AND COLD FLOW RATES, Cmax, Cmin, and Cr 5
CALCULATE TUBE-SIDE HEAT TRANSFER COEFFICIENT 5
CALCULATE AVERAGE FLOW AREA ON SHELL SIDE 5
CALCULATE SHELL-SIDE HEAT TRANSFER COEFFICIENT 5
INTERPOLATE C1 & m BOTH VERTICALLY & HORIZONTALLY 5
CALCULATE OVERALL HEAT TRANSFER COEFFICIENT 5
CALCULATE NTU 5
CALCULATE EFFECTIVENESS 5
CALCULATE OUTLET HOT WATER TEMPERATURE 5
CALCULATE OUTLET COLD WATER TEMPERATURE 5
CALCULATE PERCENTS ERROR 5
SUMMARY TABLE OF RESULTS 5
DISCUSSION OF RESULTS
HOW GOOD IS THE NTU METHOD? 5
EXPLAIN SOURCES OF ERROR 5
CONCLUSIONS 5
ORIGINAL DATASHEET 5
TOTAL 100
COMMENTS

GRADER d
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 2

MIME 3470Thermal Science Laboratory they make many passes. This experiment employs a shell-and-tube
~~~~~~~~~~~~~~ heat exchanger consisting of two tube passes and one shell pass.
Laboratory . 14
THEORY: HEAT EXCHANGER ANALYSIS
SHELL-AND-TUBE HEAT EXCHANGER Thermodynamics and the First Law dictate the overall energy
~~~~~~~~~~~~~~ transfer in a heat exchanger. There are two widely used methods of
LAB PARTNERS: NAME NAME heat exchanger analysis, the NTU-Effectiveness method and the
NAME NAME Log-Mean-Temperature-Difference (LMTD) method. These are
NAME NAME briefly discussed below.
SECTION Log-Mean-Temperature-Difference (LMTD) Method
EXPERIMENT TIME/DATE: TIME, DATE For a heat exchanger between two fluids with given inlet and outlet
IMPORTANTWhen using the Heat Exchanger Performance Test temperatures, there are three equations for the rate of heat transfer, Q,
Bench, there are some important items to remember for your
safety and the safety of others. Q = Rate of heat transfer, W
1. Make sure the proper inlet and outlet valves are open = m 1 p

c T1,i T1,o
1

before the heat exchanger is operated. Failure to do this will
pressurize the system and rupture the heat exchanger seams. As
= c T2,i T2,o
m
a rule of thumb, do not close any of the outlet ball valves more 2 p2
than half way. In particular, make sure the outlet valves that
allow the water to go to the drain are open prior to turning on
UA
T1,i T2,o T1,o T2,i
water.
2. For meaningful data, bleed taps will need to be T1,i T2,o
opened and closed to allow air to escape while the = ln
experiment is going on. Outlet valves may be closed T1,o T2,i

SLIGHTLY to help keep the heat exchanger full.
OBJECTIVE of this experiment is to measure the two inlet tempera- Tlm
tures and the mass flows through the shell and tubes, in order to predict m

where, j = mass flow rate of fluid j, kg/s
the two outlet temperatures using the NTU method and compare these
predicted values with actual measured outlet temperatures. cp = specific heat of fluid j, J/(kgK)
j
INTRODUCTIONMany engineering applications involve a
T = temperature, C
process of heat exchange between two fluids. Heat exchangers are
i inlet o outlet
devices used to promote the heat transferred between two fluids; e.g.,
a car radiator and the condenser units on air conditioning systems. U = overall heat transfer coefficient, W/(m2K)
Space heating, air conditioning, power production, and chemical A = area of surface across heat transfer occurs, m2
processing are typical areas of application. For known specific heats, U, A, and entering temperatures, the
There are many heat exchanger designs. The laboratory setup for three equations above can be solved for three unknownsT1,o, T2,o,
this experiment contains three heat exchanger types: a shell-and-tube and Q by successive substitution of one of the equations for Q onto
exchanger, a concentric tube exchanger, and a tube bank exchanger another. It is a simple matter to use the log-mean-temperature-
in cross flow. This particular experiment employs the shell-and-tube difference method of heat exchanger analysis when the fluid inlet
type heat exchanger (see Figure 1). A shell-and-tube heat exchanger temperatures are known and the outlet temperatures are specified or
is constructed of tubes that are attached on each end by a plate, called readily determined from the energy balance expressions. The value
the tube sheet, through which the tubes pass. One fluid streams into of Tlm for the exchanger may then be determined. However, if only
the inlet of the heat exchanger, flows through the tubes, and exits the inlet temperatures are known, use of the LMTD method requires
through the tube sheet at the opposite end of the heat exchanger. an iterative procedure. In such cases, it is preferable to use an
alternative approach, termed the NTU-Effectiveness method.
NTU-EFFECTIVENESS METHODOften, when working with a given
heat exchanger one must predict the outlet temperatures given the
inlet temperatures. As the dimensions of the exchanger are known, the
NTU-effectiveness method is a popular way to perform this task. This
is an easy method to calculate the overall heat transfer rate, Q. The
number of (heat) transfer units, NTU, is a dimensionless parameter
which precipitates form the heat exchanger analysis and is defined as:
Figure 1Schematic of shell-and-tube exchanger
UA
A shell encloses the internal volume where the tubes are housed. NTU , (1)
Another, fluid flows through the shell and heat is exchanged between C min
the tube-side fluid and the shell-side fluid. In a power plant, most heat where
exchangers are of the shell-and-tube design. The number of passes U Overall heat transfer coefficient (W/m2K)
commonly presents a further description of a shell-and-tube heat A Area of heat transfer (m2)
exchanger. A single pass means the fluid flows straight through the
entire heat exchanger without changing direction and so, in this CC = m C cp
C (2a)
design, the fluid moves past the length of the heat exchanger only a Cold fluid heat capacity rate
single time. In a two-pass heat exchanger the fluid in the tubes goes in CH = m H cp
H (2b)
one end, flows to the other end, reverses direction then flows back to
the same end that the fluid entered through a second set of tubes. Hot fluid heat capacity rate
Thus, the fluid travels the full length of the heat exchanger twice. Cmin = min(CC, CH)
Similarly, multiple pass heat exchangers are so named because Smaller of the two heat capacity rates (W/K)
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 3

Cmax = max(CC, CH)
Larger of the two heat capacity rates (W/K)
Note that NTU is a function of geometric and material properties,
and the mass flow rates. It does not include any fluid temperatures.
Using the calculated NTU, the effectiveness of the heat exchanger, ,
can be calculated from tables where the effectiveness formulae for
different heat exchanger arrangements can be found. In such tables,
another dimensionless term that precipitates from the analyses
appears. This is the heat capacity rate ratio, Cr = Cmin/Cmax. For a
shell-and-tube exchanger with one shell pass and some multiple of
two tube passes, the effectiveness is
1/ 2
NTU 1 C r2
2 1/ 2 1 e
21 C r 1 C r
1 e NTU 1 C r2
1/ 2
ture are noted. This is the steady-state conditionuse only the
associated flow rates and temperatures for calculations.
DETAILED COMPUTATIONAL PROCEDURE
The NTU method will be described using just one tube; but that
single tube could represent an entire tube bundle. The NTU method
calculation procedure for a shell-and-tube heat exchanger follows:
1. a. Determine cold and hot water flow rates, m H and m C (from
rotameter readings), and their specific heats, c p H and c p C
(look up values based on the average of the inlet and outlet
tempe-ratures). The units of mass flow, m
, are kg/s and those
1
of specific heat, cp, are J/(kgK). [NOTE: Some tables list
specific heat as kJ/(kgK)so always check units!!]
.
Hot water inlet thermometer

Cold water Cold water

Heat Exchanger Effectivenessis defined as outlet inlet

Actual rate of heat transfer

thermometer thermometer

Qactual

Qmax Maximum possible rate of heat transfer that an

exchanger of infinite heat transfer area
would have if it had the same inlet temps, flow
Distance between Tube Sheets, 16-1/8
(inside face to inside face)
5 Baffles, 1.2 thick. Equally spaced to form 6

chamber. 23 tube penetrations per baffle.
30 Tubes, each 0.25 diameter

rates, & specific heats as actual case

neglect wall thickness
Hot water
outlet Shell: 5 OD

thermometer 4.5 ID

The maximum heat transfer occurs in the fluid with the least The width of the
capacity to absorb or give off heat. This is the fluid with the flow course
minimum value of m
C p = Cmin. If this fluid is the cold fluid, varies & thus
the average
its temperature cannot rise above the hot-side, inlet temperature. velocity
Alternately, if the fluid is the hot fluid, it cannot be cooled below
S
the cold-side, inlet temperature. Thus, T

Qactual Qactual S = 0.475

Qmax m c p min
Thot ,in Tcold ,in .
S
L
L
S = 0.548
T

S S = 0.548
As the actual heat transfer is the same for both fluidsone D D

gaining thermal energy and the other loosing an equal amount Figure 2 Experimental apparatus with dimensional data
the actual heat transfer rate is defined by both
C TC ,o TC ,i
Qactual m
cp
b. Calculate a temperature specific energy flow known as the
heat capacity rate, C, for both the cold and hot flows
Qactual m
c p TH ,i TH ,o .

Ccold m cold c pcold The larger of these is Cmax

and H
These last two relations yield the outlet temperatures desired.

LABORATORY PROCEDURE
1. Verify the dimensions and features of Figure 2. .

Chot m hot c phot and the smaller Cmin

2. Generally, small flow rates will generate better results but may
take longer to reach steady state. Also, do not let the air that comes
out of entrainment accumulate in shell. Use bleed taps as needed.
3. For a hot water flow of about 15% of the maximum rotameter
reading and a cold water flow of about 30%, take inlet and outlet
temperatures of both flows until no further changes in tempera- c. Calculate the heat capacity rate ratio, Cr = Cmin/Cmax.
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 4

2. Calculate the heat transfer coefficients at the inside and outside 1.25 1.5 2.0 3.0
SL/D C1 m C1 m C1 m C1 m
surfaces of the tubes, hinside and houtside. These are used to compute 0.600 0.213 0.636
the overall heat transfer coefficient, U. (See Figure 3) 0.900 0.446 0.571 0.401 0.518
1.000 0.497 0.558
houtside 1.125 0.478 0.565 0.518 0.560
1.250 0.518 0.556 0.505 0.554 0.519 0.556 0.522 0.562
1.500 0.451 0.568 0.460 0.562 0.452 0.568 0.488 0.568
hinside 2.000 0.404 0.572 0.416 0.568 0.482 0.556 0.449 0.570
3.000 0.310 0.592 0.356 0.580 0.440 0.562 0.428 0.574
Table 1Constants of for airflow over a staggered tube bank

SL SD
Figure 3Heat transfer coefficients at inside and outside tube surfaces

D
a. Flow Inside Tubes: Even though there are many tubes in the
bundle and there are parallel and counter flows in this two-pass
exchanger, the calculation may be performed by considering the ST
flow in just one of the tubes WITH THE CAVEAT THAT one must
account for the direction of the flow. That is, half of the tubes are Vavg, T
associated with parallel flow and half the tubes are associated A2
with counterflow. Thus, the mass flow in the equivalent tubes is A1
m
total tube - side flow
m
inside 1 tube
N 2
where, N = total number of tubes.
From simple flow relations, it is known that the velocity Figure 4Staggered tube arrangement
inside a single tube is
Re D ,max Vmax D / is defined for the maximum
m inside
Vinside velocity occurring within the tube bank, Vmax, which occurs
A
at one of two locationseither in way of A1 or A2 (see
where, A = cross sectional area of one tube. Figure 4). The maximum velocity will occur at A2 if
2 S D D S T D . The factor of 2 results from the
Given this velocity, a Reynolds number (
Re Vinside D ) can be computed to indicate whether
bifurcation experienced by the fluid moving form the A1 to
the inside flow is laminar or turbulent. This will most likely
be fully-developed, laminar flow. For such with constant the A2 planes. In this case,
surface temperature, Ts, and Pr ~ 0.6 : Vmax S T 2 S D D Vavg , otherwise it occurs at
Nu D 3.66
A1 and Vmax S T ST D V avg .
where fluid properties are based on the mean (or bulk)
temperature across a cross section, Tm. Note: The average velocity of flow over the tube is not
If the flow is fully developed, turbulent (Re 10,000), constant as the shell is not wall-sided but circular. Thus,
one needs to use some average value of area. To use the

n 0.4, Ts Tm relations for staggered tube arrangements, a free-stream, shell-

NuD 0.023Re4D/ 5 Prn

side, fluid velocity must be determined. As the sides of the shell

. are circular, this free-stream velocity varies. Thus, an average

n 0.3, Ts Tm
free-stream velocity must be determined based on an average
width of the shell, wavg. This can be obtained from simple
integration as
r
Tube-side fluid properties should be evaluated at the r 1 1

Tm,i Tm,o 2
2 r x

2
2
dx
average of the mean temperatures, Tm . w avg
0

2 r
1 dx

0
At this point, wavg is determined and an answer could be listed as w avg 1.571
b. Shell Flow Outside of Tubes: For the staggered tube
arrangement of the experiment shown in Figure 4, use the Allternately, the expression above could be selected and then
choose SYMBOLICS: EVALUATE : SYMBOLICALLY
1
following expression for the average Nusselt number from the menu to yield w avg
2
r

Nu D 1.13C1 Re m
D ,max Pr 1/ 3
.
Multiplying this with the distance between baffles gives an
(3)
average cross-sectional area, Aavg, for the flow and the
Use Table 1 to determine m and C1. Note in the report which
average velocity, Vavg, can be determined from V =
values of m and C1 were used. This relation applies when there
are more than 10 tubes in a bundle (NL 10), 2000 < ReD,max < AavgVavg.
40,000 where ReD,max is defined below, and Pr 0.7. average 3. a. Calculate the overall heat transfer coefficient, U
mean temperature of the fluid, Tm , as defined above.
ST/D
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 5

1
U
1 t 1

hinner k tubes houter

0
Assume tubes
are thin - walled
& very conductive
where, t = the tubing thickness
Then NTU is

This value
UAtube surface
NTU should be
Cmin
dimensionless
Now, the heat exchanger effectiveness, , can be determined.
For one shell pass and two tube passes the effectiveness is

1
1/ 2

NTU 1 C r2
1 / 2 1 e
21 C r 1 C r2 .

1 e NTU 1 C r
2 1/ 2


PHYSICAL PROPERTIESAs the liquid (water) is moving, it
must be under a slight pressure. This experiment is interested in the
properties of liquid water density and specific heat which are both
functions of temperature and pressure. However, at low pressures,
one may assume that density and internal energy are approximately
equal to their saturated liquid values at the same temperature; i.e.,
(T, p) f(T) and u(T, p) uf(T). Thus, density can be defined.
Enthalpy is, h(T, p) hf(T) + [p psat(T)]/f(T). At a room temperature
of, say, 70F (~21C), psat = 0.02487bar. Compared to atmospheric
pressure of 1.01325bar, this is small and negligible. Thus,
h(T, p) hf(T) + p/f(T). At the temperature assumed, the density of
water is 998kg/m3. At small pressures, say 2atm = 2.02bar,
p/f(T) = 0.202 kJ/kg while hf(T) = 88.14 kJ/kg. Thus, a fair approxi-
mation of enthalpy is h(T, p) hf(T). Finally, the definition of specific
heat is h = c(T) T; thus, C (T, p) C f(T).
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 6

FOR THE REPORT
1. Be sure to clearly state/show the calculations along with any
assumptions made on the Mathcad worksheet in the order
appearing on the grading sheet. Of course, you may have other
intermediate calculations.
2. Indicate sources of error in equations as they apply to the shell-
and-tube heat exchanger in the lab, as well as sources of error in
the measurements.
3. Discuss how good is the NTU method.
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 7

ORDERED DATA, CALCULATIONS, and RESULTS The object below is reduced to 70% of full size.
MATHCAD OBJECT--DOUBLE CLICK TO OPEN

DATA

Look Up (& Interpolate) Physical Properties For The 2 Mean Temperatures Calculated At The Right

1a. Determine Flow Rates Of Hot And Cold Fluids

1b. Calculate Heat Capacity Rates, The MAX & MIN Heat Capacity Rates,
& The Heat Capacity Rate Ratio

2a. Calculate Heat Transfer Coefficient For Tube Side

2b. Calculate Heat Transfer Coefficient For Shell Side

3a. Calculate Heat Exchanger Effectiveness

The Measured Outlet Temperatures Were

3b. Calculate Outlet Temperatures
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 8

DISCUSSION OF RESULTS CONCLUSIONS

Discuss how good is the NTU method.

Indicate sources of error in equations as they apply to the shell-

and-tube heat exchanger in the lab, as well as sources of error in
the measurements
Last Rev.: 11 JUN 08 SHELL & TUBE HEAT EXCHANGER : MIME 3470 Page 9

APPENDICES
APPENDIX ADATA SHEET FOR SHELL-AND-TUBE HEAT EXCHANGER LAB

Time/Date: ___________________________

Lab Partners: ___________________________ ___________________________

___________________________ ___________________________

Verify supplied dimensions given in Figure 2. Is anything else needed?

Is the hot flow on the tube side or shell side? ______________ Rotameter max flow rate: ________________
Cold Hot
Volumetric Volumetric Hot Outlet Hot Inlet Cold Outlet Cold Inlet
Flow Rate, Flow Rate, Temperature, Temperature, Temperature, Temperature,
Run
V C V H T H ,o T H ,i TC ,o TC ,i
( % of max ( % of max (C) (C) (C) (C)
rotameter rating) rotameter rating)
1

APPENDIX BPHYSICAL PROPERTIES TABLE