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 600
o
C (1100
o
F) or even 650
o
C
Minimum -100
o
C (-150
o
F)
Fluids
Subject to materials
Available in a wide range of materials
Size per unit 100 - 10000 ft
2
(10 - 1000 m
2
)
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

U = Overall heat transfer coefficient
A = Area of the tube
T = 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
H
Q
and
C
Q

and to select the set of values where
C
Q
is closest to
H
Q
.
Hot water flow rate (
W
H
)
H
Q
=
) (
2 1
t t Cp F
H H


Cold water flow rate (
W
C
)
C
Q
=
) (
1 2
T T Cp F
C C


where:

H
Q
= Heat load for hot water flow rate

C
Q
= Heat load for cold water flow rate

H
F
Hot water mass flow rate

C
F
Cold water mass flow rate

1
t
Hot water inlet temperature

2
t
Hot water outlet temperature

1
T
Cold water inlet temperature

2
T
Cold water outlet temperature


Log mean temperature difference (LMTD)
) (
) (
ln
) ( ) (
1 2
2 1
1 2 2 1
T t
T t
T t T t
LMTD

) (
) (
1 2
2 1
t t
T t
R

) (
) (
1 1
1 2
t T
t t
S

The corrected LMTD= FT x LMTD calculated above

Overall heat transfer coefficient,
U

Overall heat transfer coefficient at which equivalent to
D
U
can be calculated by using equation
LMTD A
Q
U

Where:

Q
Heat rate with respect to the flow rate of water
H
Q
or
C
Q

Theoretically Q above is equal to
H
Q
or
C
Q

If there any error in temperature collected, it is recommended to calculate
ave
U
value based on
equation of
) ( 5 . 0
H C
Q Q Q
that will give an average value.






Reynolds Number
Shell-side Re(s) for C
W

Gs De
s
.
) Re(

12
de
De

do
do
PT PT
de
. 2 / 1
)
4
. 2 / 1 86 . 0 2 / 1 ( 4
2

Where:

PT
Pitch = 0.81inch

do
Tube outside diameter, inch


Viscosity, taken at average fluid temperature in the shell, lbmft
-1
hr
-1

As
Ws
Gs

(lbmft
-2
hr
-1
)

Ws
Flow rate in (lbmhr
-1
)
Tube-side Re (t) for H
W

Gt D
t
.
) Re(

Where:


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





Heat Transfer Coefficient
Both values of internal heat transfer coefficient,
hi
and outside heat transfer coefficient,
ho
obtained from equation below:

14 . 0 3 . 1
) .( )
.
.(
.

W
Cp
k
De
k jH
ho

And

14 . 0 3 . 1
) .( )
.
.(
.

W
Cp
k
D
k jH
hi


Where:

k
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

jH
Energy being transfer in the system

Therefore, the dirt factor,
Rd
value :

D C
D C
U U
U U
Rd
.

Where:

C
U
Clean overall heat transfer coefficient from both individual inside and
outside fluids

D
U
Overall heat transfer coefficient obtained from calculation in part 1
From the equation before, U
C
value is calculated from heat transfer coefficients, the Reynolds
number (i.e flow rates), the flowing fluids properties and the Heat Exchanger diameters.
D
U 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
D
U
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:
W
H
: The measured tube-inside pressure drop DP (tube) which will be corrected and is
expected to be more than calculated tube-side pressure drop.
W
C
: 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) : Flow Transmitter for HW. Vortex flow meter, 0-30 USGPM
FT (C) : Flow Transmitter for CW. Magnetic flow meter, 0-30 USGPM.
DPT : Differential Pressure Transmitter for Shell/Tube side Pressure
drop, 0-5000 mm H
2
O.
TE1 to TE5 : Temperature Element Resistance Temperature Detector
(RTD), for t
1
, t
2
, T1, T2 TIC5 respectively, 0-100
0
C.
PG-H, PG-C : Pressure gauges, 0-60 psig.
TG2 : Temperature gauge, 0-100
0
C.
TSV3A, TSV3B : Temperature Solenoid Valve.
Panel-Mount
FI (H), FI (C) : Flow Indicator for HW, CW. Digital display, 0-30 USPGM
TI1, TI2, TI4 : Temperature Indicator for TE1, TE2, TE4, displaying t
1
, t
2
and
T2 respectively. Digital display, 0-100
0
C
TI3 (T1)/TIC3 : Temperature Indicator with ON/OFF control for TE3 i.e. T1.
Digital display, 0-100
0
C
TIC5 : Temperature Indicator with ON/OFF control for TE5.
Digital display, 0-100
0
C
DPI : Differential Pressure Indicator for DP (Shell) and DP (Tube) of
Heat Exchanger. Digital display, 0-5000 mm H
2
O

Portable
FTDPR : Flow, Temperature, Deferential Pressure Recorder, 12-
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 (t
2
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 5% 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 HW, FH
III 10USGPM 15 USGPM
IV 10USGPM 10USGPM
(C2 ) Experimental Procedures
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 SET 1 SET 2 SET 3
CW HW CW HW CW HW
Nominal Flow, USGPM
Actual Flow, USGPM
Temp, C, Inlet
Temp, C, Outlet
FC: 10

FC: 9.8

T13: T
1
: 28.6

T14: T
2
: 52.3
FH: 15

FH: 15.3

T11: t
1
: 65.4

T12: t
2
: 52.4

10

9.9

28.7

46.9

15

15.3

58.6

48.1

10

9.9

28.7

46.9

15

15.2

54.0

44.8

Pressure, psig, Inlet

Pressure drop, mm H2O
PG-C: 2.5
DP: 597 (SHELL)
PG-H: 4.7
DP:1454(TUBE
)

2.5
621

4.5

1477

2.5

632

4.5

1487
* Temp change, C

* Average Temp, C

*Q, Head load, BTU/HR
23.7

40.45

QC:209472.97
13.2

59.6

QH:179385.92
18.8

37.7

162502.54
11.8

54.1

144888.63
16.1

36.35

162403.33
9.9

50.55

126120.30
QC/QH 1.168 1.122 1.288
Select QC/QH nearest to
1.0
SELECTED NOT SELECTED NOT SELECTED
Selected set,

0.5(QC+QH), BTU/HR

194429.45










Table 2: experimental data for RUN IV
RUN IV SET 1 SET 2 SET 3
CW HW CW HW CW HW
Nominal Flow,USGPM
Actual Flow, USGPM
Temp, C, Inlet
Temp, C, Outlet
FC: 10

FC: 9.8

T13: T
1
: 29.3

T14: T
2
: 50.4
FH: 10

FH: 10.5

T11: t
1
: 66.8

T12: t
2
: 50.7

10

9.8

29.4

46.0

10

10.4

61.2

47.1

10

9.8

29.4

44.6

10

10.4

58.8

45.8

Pressure, psig, Inlet

Pressure drop, mm H2O
PG-C: 2.5
DP: 605 (SHELL)
PG-H: 2.0
DP: 564(TUBE)

2.5
620

2.0

673

2.5

627

2.0

578
* Temp change, C

* Average Temp, C

*Q, Head load, BTU/HR
21.1

39.85

QC:186492.81
16.1

58.75

QH:152464.50
16.6

37.7

146719.47
14.1

54.15

132253.15
15.2

37.00

134345.53
13.0

52.3

121935.53
QC/QH 1.22 1.109 1.101
Select QC/QH nearest to
1.0
NOT SELECTED NOT SELECTED SELECTED
Selected set,

0.5(QC+QH), BTU/HR

128140.53

Table 3 : calculated value for heat load, LMTD and U
RUN QC (BTU/hr) QH (BTU/hr)
0.5(QC+QH)
(BTU/hr)
LMTD*FT
(F)
U (

)
III 209472.97 179385.92 194429.45 20.14 504.81
IV 134345.53 121935.53 128140.53 25.50 332.70



Table 4: calculated Reynolds number
RUN
Actual Flow
(USGPM)
Re (s) Re (t)
III
FC: 9.8
FH: 15.3
389.31 12833.12
IV

FC: 9.8
FH: 10.4
364.46 7753.94

Table 5: Calculated Heat Transfer Coefficient and Dirt Factor
RUN
h
o

(

)
h
i
(

)
h
io
(

)
U
c
(

)
U
d
(

)
R
d

(x10
-3
)
III 1598.82 721.68 571.57 421.05 504.81 3.94
IV 1620.18 604.95 479.12 263.63 332.70 0.664

Table 6: Calculated Pressure Drop
RUN
Pressure Drop
Shell-side (mmH
2
O) Tube-side (mmH
2
O)
Calculated Measured Corrected Calculated Measured Corrected
III 4937.73 560 65.05 89.891 1093 353.72
IV 4484.88 564 69.05 18.79 563.32 191.88




CALCULATION
Sample calculation
RUN III, Set 1
Heat Load and Heat Balance
FC= 9.8 USPGM
FC= 9.8 USGPM x m
3
/Hr 1000 Kg 2.20462 Ibm
4.4 USGPM m
3
kg
FC= 4910.29 Ibm/hr
CP= 1 Btu/Ibm
o
F
QC= FC C
P
(T2-T1)
Convertion unit of temp.
T2 = 44.6
o
C = 44.6(1.8) + 32 = 112.28
o
F
T1 = 29.4
o
C = 29.4(1.8) + 32 = 84.92
o
F

= 4910.29 Ibm/hr x 1 Btu/Ibm
o
F x (112.28 84.92
o
F
= 209472.97Btu/hr

FH = 15.3 USPGM
FH = 15.3 USGPM m
3
/Hr 1000 Kg 2.20462 Ibm
4.4 USGPM m3 kg
FH = 7666.065Ibm/hr
CP= 1 Btu/Ibm
o
F
QH= FH X C
P
X (t1 - t2)

Conversion unit of temp.
t2 = 45.8
o
C = 45.8(1.8) + 32 = 114.44
o
F
t1 = 58.8
o
C = 58.8(1.8) + 32 = 137.84
o
F
=7666.065 Ibm/hr x 1 Btu/Ibm
o
F x (137.84 114.44)
o
F
= 179385.92Btu/hr
Ratio QC/QH =

= 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)

LMTD =
()()

()
()
= 25.33
Correction factor, F
T
is obtained from figure 18 (appendices) based on the value of R and S,
where F
T
= 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 ft
2

Q = 0.5(QC+QH)
Q = 0.5 (209472.97 + 179385.92)
Q = 194429.45(BTU/hr)
(

) 5 (

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)
()

Given, d
o
= 0.625 ins
P
t
= 0.8125 ins
W
s
= 4910.29 lbm/hr
A
s
= 0.029 ft
2

= 1.584 lbm/ft.hr
G
s
= 4910.29 /0.029 = 169320.34 lbm/hr.ft
2



d
e
= 0.537838 ins x 0.08333 = 0.0443 ft
D
e
= 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)
()

Given, D = 0.04125 ft
W
t
= 7666.065 lbm/hr
A
t
= 0.02139
= 1.152 lbm/ft.hr
G
t
= 7666.065/0.02139 = 358394.81 lbm/hr.ft
2


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

8.3 Heat Transfer Coefficient, h
i
and h
o
, U
c
, U
d
and R
d
Calculation of h
o
for shell-side (CW) (RUN III, Set 1)
Given, D
e
= 0.003733 ft
C
p
1.001 btu/lbm.F
k = 0.36462 btu/hr.ft
2
. F/ft (at T
avg
= 40.45C)
= 1.584 lbm/ft.hr
T
wall
=( 40.45+59.6)
O
C/2=50.03
0
C

wall
= 2.412lbm/ft.hr (at T
wall
)

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

()

( )

h
o
= 1598.82 (

)

Calculation of h
i
for tube-side (HW) (RUN III, Set 1)
Given, D = 0.04125 ft
C
p
1.001 btu/lbm.F
k = 0.37871 btu/hr.ft
2
. F/ft (at T
avg
= 59.6 C)
= 1.152 lbm/ft.hr

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

( )

h
i
= 721.68(

)

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

= 571.57

= 421.05

Calculation of Dirt Factor, R
d
(RUN III, Set 1)
U
d
= 504.81

U
c
= 421.05

R
d
=

= 3.94x 10
-4



8.4 Pressure Drop
Conversion: 1 psi = 2.3088ft = 27.72 ins = 703.72 mmH
2
O at 60F (SG=1.0)

Shell side pressure drop (RUN III, Set 1)
P
s
=

()

Given, D
s
= ID = 6.065ins = 0.50541 ft
N = 23
g = 4.17 x 10
8
ft/hr
2

= 62.0348 lbm/ft
3
(at T
avg
= 40.45C)
D
e
= 0.003733 ft
G
s
= 169320.34 lbm/ft
2
.hr
SG = 0.9931 (at T
avg
= 40.45C)

s
= 1.01167
= 0.0052 (at Re(s) = 389.31)

P
s
=

()
(

)
= 9.2550 psi



Since SG = 0.9931,
1psi = 703.72 x 0.9931 = 698.86 mmH
2
O
P
s
= 9.2550 psi x 698.86 mmH
2
O / 1 psi = 4937.73 mmH
2
O

Correction to the measured pressure drop for Shell side, CW (RUN III, Set 1)
Pressure drop read at 560 mmH
2
O and flow rate CW of 9.8 USGPM,
Calculated piping pressure drop DP(s) = 494.95 mmH
2
O

P (corrected) = 560-494.95 = 65.05mmH
2
O


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

P
t
=

Given, D = 0.04125 ft
L x n = 12
= 61.392 lbm/ft
3
(at T
avg
= 59.6C)
G
t
= 358394.81 lbm/hr.ft
2

SG = 0.98671(at T
avg
= 59.6C)

t
= 0.9893
= 0.00012 (at Re
(t)
= 12833.12)

P
t
=

)
= 0.1295 psi

Since SG = 0.98671,
1psi = 703.72 x 0.9871 = 694.14 mmH
2
O

P
t
= 0.1295 psi x 694.14 mmH
2
O / 1 psi = 89.891 mmH
2
O


P
r
=(

) (

) (

),
Where (

) (

)= 0.02 (at G
t
= 358394.81 from figure 27 in appendices)
P
r
= (
()

) 0.02 = 0.1622psi x 694.14 mmH

2
O / 1 psi = 112.56 mmH
2
O

= 89.891+ 112.56= 202.45mmH

2
O

Correction to the measured pressure drop for Tube side, HW (RUN III, Set 1)
Pressure drop read at 1093 mmH
2
O and flow rate CW of 15.3USGPM,
Calculated piping pressure drop, DP (t) = 739.28 mmH
2
O

P (corrected) 1093-739.28 = 353.72 mmH
2
O




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
0
C and
70
0
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
/Q
H
which nearest to 1.0
is selected to continue the calculation. Then, for RUN III, set 1 is selected. The Q
C
is 209472.97
Btu/hr ,Q
H
is 179385.92 Btu/hr and 0.5(QC+QH) is 194429.45 Btu/hr. Next, the corrected LMTD
was 20.14
0
F while the overall heat transfer coefficient is 504.81 (

). The Reynolds
number for shell is 389.31 and for tube is 12833.12.Other than that, for part III value h
o,
h
i
and
h
i0
are 1598.2(

), 721.68(

) and 571.57(

) respectively. For U
C
the value is
421.05 (

) and U
D
is 504.8(

).The value of R
D
is 3.94 x x10
-3
.Next, for the pressure
drop at shell-side the calculated value, measured and corrected are 4973.73 mmH
2
O,560
mmH
2
O and 65.05 mmH
2
O respectively. For the pressure drop at tube-side the calculated
value, measured and corrected are 89.891 mmH
2
O,1093 mmH
2
O and 353.72mmH
2
O
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 Q
C
/Q
H
is nearest to 1.0 which is 1.101. The Q
C
is
134345.53 Btu/hr ,Q
H
is 121935.53 Btu/hr and 0.5(QC+QH) is 128140.53 Btu/hr. Next, the
corrected LMTD was 25.5
0
F while the overall heat transfer coefficient is 332.7(

). The
Reynolds number for shell is 364.46 and for tube is 7753.94.Other than that, for part III the h
o,
h
i
and h
i0
are 1620.18(

), 604.95(

) and 479.12(

) respectively. For U
C
the
value is 263.63(

) and U
D
is 332.70(

). The value of R
D
is 0.6604 x x10
-3
.Next, for
the pressure drop at shell-side the calculated value, measured and corrected are
4484.88mmH
2
O,564mmH
2
O and 69.05 mmH
2
O respectively. For the pressure drop at tube-side
the calculated value, measured and corrected are 18.79mmH
2
O,563.32mmH
2
O and
191.88mmH
2
O 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_and_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-exchanger-
theory.html#sthash.z1rLpGBV.dpuf
http://www.engineeringtoolbox.com/overall-heat-transfer-coefficients-d_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)

DENSITY
lbm/ft3

DENSITY
lbm/USG

VISCOSITY
lbm/ft. sec

HEAT
CAPACITY
BTU/lbm.
F

THERMAL
CONDUCTIVITY
BTU/hr.ft2.
F/ft
71.1 61.00 8.156 2.6947 x 10-4 0.3840
65 0.985 61.30 8.182 2.9272 x 10-4 1.00 0.3830
60 61.38 8.207 3.1503 x 10-4 0.3790
54.5 0.9872 8.227 3.430 x 10-4
48.9 0.9901 61.71 8.253 3.7565 x 10-4 0.3710
48 3.8223 x 10-4
40 61.94 8.289 4.4083 x 10-4
35 0.995 62.06 8.296 4.8572 x 10-4 0.999 0.3605