IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 2, JULY /2017

ISSN (ONLINE): 2394-8442

THERMAL DESIGN, MATHEMATICAL MODELLING, CFD ANALYSIS&

EXPERIMENTATION OF COIL IN SHELL SAMPLE COOLER
SWAPNIL S.CHILHAL1,SUNIL CHOUGULE2,ABHIJEET DESHPANDE3,KAUSHIK KALE4
[1, 2]
Department of Mechanical Engineering, Vishwakarma Institute of Technology Pune, Maharashtra, India 411037
[3, 4]
Research & Development, Forbes Marshall Pvt. Ltd. Pune, Maharashtra, India 411018
swapnilchilhal1993@gmail.com , sunil.chougule@vit.edu2, adeshpande@forbesmarshall.com3, kkaushik@forbesmarshall.com4
1

ABSTRACT.

The importance of coil in shell sample cooler has been recognized in many industrial applications
ranging from petrochemical, steam and water sampling system (SWAS). The presented study is focused on the
thermal design, Mathematical modeling and CFD analysis of coil and shell sample cooler. Heat transfer area of a
sample cooler shell is calculated using the basic equation for thermal design of a heat exchanger. The mathematical
code for finding the length of heat transfer, which is based on sample outlet temperature requirement, is developed
in Scilab 5.5.2 by using the different correlations that depend on the Reynolds number, Prandtl number, type of fluid
medium and geometrical parameters. In this present study, a coil in shell sample cooler has been modeled for
different fluid flow rates. CFD analysis has been carried out for a coil in shell sample cooler. The geometry was
developed in catia-v5 with meshing performed in Fluid-flow workbench 16.0. Experiment is carried out on counter
flow sample cooler, consisting of large numbers of helical coil layers with a length of 6m and tube diameter
1(25.4mm). The experiment is performed under controlled environmental condition. The hot water flows at sample
side and cold water at the cold side. The temperature for the water inlet is fixed at 35 deg C for different samples as
well as water flow rates. The key points for the analysis are the sample outlet temperatures and pressure drops for
cold side. The result obtained from the experiment is stored in data acquisition system which gives the outputs such
as heat duty, flow rates, drop in pressure and temperature for the sample cooler.

Keywords coil in shell sample cooler;Scilab 5.5.2; catia-v5; Ansys Fluent 16.0;Ansys Workbench Fluid Flow16.0;

I. INTRODUCTION
The coil in shell sample cooler is constructed using circular layers of helically corrugated tubes placed inside a light compact shell. The fluid in
each layer flows in the opposite direction to the layer surrounding it, producing a criss-cross pattern. The large number of closely packed tubes
creates a significant heat transfer surface within a light compact shell. The alternate layers create a uniform heating of fluids increasing the total
heat transfer coefficient. The corrugated tubes produce a turbulent flow where the desired feature of fluctuating velocities is achieved. The
connection locations and angle of entry is specially selected to reduce the probability of debris buildup. Coil in shell heat exchanger are highly
efficient over low space. But under the conditions of low flow rates (Laminar Flow) the typical shell-and-tube exchangers have low heat-transfer
coefficients and hence are uneconomical. In coil in shell heat exchanger increase in pipe diameter, causes higher heat transfer coefficient and
lower pressure drop. This effect is due to the influence of secondary flow. Applications: Heating systems, Steam water analysis system (SWAS),
Refineries, Petrochemical industries.

II. LITRATURE REVIEW

There are diverse study and research that describes the thermal design and CFD analysis for coil in shell sample cooler. Hence it calls for to
develop an optimum mathematical model for coil in shell sample cooler which can adopt any design and fluid requirements at various stages of
process industries. N.E.Wijeysundera,[1]presented a detail investigation on performance of a compact, spiral coil heat exchanger. He developed
numerical model for vertical helical coil heat exchanger, which calculated the heat transfer and pressure drop. The experimental data obtained
from two heat exchanger tested under several operating conditions proved to be helpful for validating the model developed. Purushottam Shelke
[2] presented a research work on analysis of counter flow helical coil heat exchanger.

To Cite This Article: SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK

KALE,. THERMAL DESIGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF
COIL IN SHELL SAMPLE COOLER. Journal for Advanced Research in Applied Sciences ;Pages: 25-30
26. SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK KALE,. THERMAL
DESIGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF COIL IN SHELL
SAMPLE COOLER. Journal for Advanced Research in Applied Sciences; Pages: 25-30

It was found that because of the curvature nature of the coil led to development of the centrifugal force which resulted in the secondary flow
development especially in laminar flow region. Hence the effect of these parameters on Nu number and heat transfer coefficient is presented in
this paper. It indicates that helical coils are beneficial at low Re number. Hassam Teheran [3] carried out a research on thermal performance of
shell-and-coil heat exchangers.

It shows the effect of the tube diameter, coil pitch, shell-side and tube-side mass flow rate on the performance and effectiveness of vertical
helical coiled tube heat exchangers. The results indicated that the relation of effectiveness and no of transfer units for the mixed convection heat
exchangers was the same as that of a counter-flow heat exchanger. Yasuo Mori,[4]presented a research on effect of forced convection on heat
transfer in curved pipes. In this present work analysis is made about the pipe inlet condition under uniform wall temperature from temperature
field. The result shows for both laminar and turbulent region, approximation for the Nu number in curved coil remains same under uniform heat
flux as well as wall condition.

It is observed that most of the researches use various types of co-relations and boundary conditions for thermal design and CFD analysis of
sample cooler, but there is a need for optimum method to be developed for the better performance of process industries. Hence this mathematical
model has brought the ability to solve various problems regarding the coil in shell sample cooler.

III. EXPERIMENTATION
Experiment was conducted on a coil in shell sample cooler test rig. A experimental setup of coil in shell is shown in Figure.1

Figure 1. Experimental setup of Coil in shell sample cooler

The setup primarily consists of three major parts viz., coil in shell sample cooler, and flow control valves and data acquisition system. Hot
sample which is at 90 deg C is formed in the tank by mixing of water and steam, is passed through the coil side in sample cooler and the cold
water at 35 deg C is passed through the shell side of sample cooler.The inlet as well as outlet of both the fluids are arranged in such a way that
they produce a counter flow pattern for the experimentation.

Experimental Procedure

1. Ensure all the power, fluid line, and drain line connections are checked
2. Open the cooling water flow control valve check the cooling water flow, temperature and pressure is sufficient.
3. In case leakage is observed in the cooling water supply line stops the flow rate and check for the leakage.
4. Start the cooling water supply and adjust the supply flow rate as per the requirement.
5. Operate rota meter and adjust the desired sample flow rate of rota meter.
6. In case sample flow rate is not achieved, operate the pressure regulator and check for the sample flow rate.
7. Check for the sample outlet temperature for every 15min.If the outlet is desired stop the procedure else vary the sample flow rate and check
for the outlet temperature. Reading is taken from the data acquisition system.

IV. PROPOSED METHODOLOGY

A.THERMAL DESIGN

The flow rates of both hot and cold streams, their terminal temperatures and fluid properties are the primary inputs of thermal design of sample
cooler. Thermal design of a shell and coil sample cooler typically includes the determination of heat transfer area, number of coil, coil length and
diameter, coil pitch, shell and coil side pressure drop etc. The design specification for thermal design & Mathematical model of the coil in shell
sample cooler is listed in Table 1
27. SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK KALE,. THERMAL
DESIGN,
IGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF COIL IN SHELL
SAMPLE COOLER. Journal for Advanced Research in Applied Sciences;
Sciences Pages: 25-30

Table 1. Design specification of the coil in shell sample cooler.

SR. No. Parameter UoM Hot side Water side

1 Flow Media - Hot water Cold water
2 Design Pressure Bar 50 10
3 Design Temperature deg.C 350 100
4 Fluid flow Rate Kg/hr 0-100 0-4500
4500
5 Inlet Temperature deg.C 40-120 25-55
55
6 Outlet Temperature deg.C 45-60 35-63
63
7 Pressure Drop bar 0-0.6 0-0.6
8 Material of Construction - ASME A316 ASME A316

B.MATHEMATICAL MODEL

The mathematical model (code) for determining the optimum heat transfer area for the outlet sample temperature requirement and determining
the sample outlet temp.for the given length of coil is developed in sci-lab 5.5.2. Scilab is an open source, cross--platform which is used for
statistical analysis, dynamic simulations, implicit and explicit of dynamic system.

Figure 2. Algorithm for finding optimum length of heat transfer.

This code is developed

ped by using the basic equations that are used for thermally design the coil in shell sample cooler. The effect of flow and
geometrical parameters on the length of heat transfer is analyzed by using the code

C.CFD ANALYSIS

Computational fluid dynamics (CFD) starts with the construction of desired geometry and mesh for modeling of the fluid domain.

Import the Geometry

Fluid Flow Meshing

Model Selection

Material Selection

Boundary Conditions

Model Solution

CFD Results

Figure 3.Flow chart of CFD Analysis

The basic objective of this analysis is to validate CFD model and mathematical model with experimental results. CFD analysis has been
performed for the validation approach.
28. SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK KALE,. THERMAL
DESIGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF COIL IN SHELL
SAMPLE COOLER. Journal for Advanced Research in Applied Sciences; Pages: 25-30

In the continuity equation, energy equation and Navier-stoke momentum equation governs the flow of the fluid in the curve tubes. Continuity
Equation gives the conservation of mass and is given by,

1 2 3
+ + + =0
1 2 3

+ =0

And for constant density

=0

The momentum balance follows Newtons Second law. The two forces acting on the finite elements are the body and surface forces. In CFD the
momentum equation given as,
2
+ = +
2

The governing energy equation is given by:

2
+ =
2

Sample cooler geometry built in the Catia-v5 with a sample cooler dimension mentioned in Table no 1. Model of Counter flow coil in shell
sample cooler is as shown in the fig.4.(c). Meshing is done in Ansys Workbench 16.0, fluid flow by importing the coil in shell sample cooler
geometry, using a tetrahedron meshing with the element size 3mm for solid and 8mm for fluid domain. The pressure based realizable K-
turbulent model is selected under the solution setup. The material properties of fluid and solid domain, is assigned in material model.

Cold In Hot out

Cold Out

Hot In

Figure 4.Geometry of coil in shell sample cooler

Initially, Mass flow inlet boundary condition is given to the cold as well as hot inlet and outlet boundary condition is specified by pressure outlet
for the simulation. By doing the hybrid initialization method, solution is run. Solution is conversed after the 500 iteration.
Water

Shell
Dummy

Sample

Coil

Figure 5. Meshing of coil in shell sample cooler

29. SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK KALE,. THERMAL
DESIGN,
IGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF COIL IN SHELL
SAMPLE COOLER. Journal for Advanced Research in Applied Sciences;
Sciences Pages: 25-30

V. RESULTS AND DISCUSSION

During the experimentation, the coil in shell sample cooler is tested for the design
designed shell and coil side mass flow rate. It has been seen from the
experimental results, that the given sample cooler meets
meet the required temperature and pressure condition. There is a slight variation in the
experimental and the CFD result. Therefore, the model which we simulate on the CFD is conversed. The fig.6 shows the Experimental Results on
the HMI of the PLC. Similarly, the fig.7 shows the temperature profile on coil sside.
ide. Fig.9 and Fig.10 gives pressure variation on shell and coil side.

Figure
ure 66. Experimental Result on the HMI of the PLC

Figure 7. Temperature profile of coil

Fig
Figure 8. Pressure drop across shell side

Fig
Figure 9. Pressure drop across coil side
30. SWAPNIL S.CHILHAL,SUNIL CHOUGULE,ABHIJEET DESHPANDE AND KAUSHIK KALE,. THERMAL
DESIGN, MATHEMATICAL MODELLING, CFD ANALYSIS& EXPERIMENTATION OF COIL IN SHELL
SAMPLE COOLER. Journal for Advanced Research in Applied Sciences; Pages: 25-30

VI. CONCLUSION
This paper presents the Thermal Design, Mathematical Model and CFD analysis of the coil in shell sample cooler. The Experimental result that
is obtained from sample cooler converges with the Mathematical Model and CFD Model. It has been observed that the correlations in the
developed Mathematical Model are suitable for designing the coil in shell sample cooler.

Mathematical Model for coil in shell sample cooler is applicable for the different densities and viscosities of fluid. From the mathematical
model, the effect of geometrical parameter, thermo-physical properties and mass flow rates on the length of heat transfer is analysed. It has been
observed, that as we increase the outside diameter (do) and inside helical diameter (dc) of the coil, the length of the heat transfer decreases.
Similarly, as we increase the mass flow rate of hot side (coil), the length of coil increases linearly.

VII. ACKNOWLEDGMENT
I am sincerely grateful to Forbes Marshall Pvt.Ltd, Pimpri- Pune for extending the support to complete this research work.

REFRANCES
1. J.C.Ho, N.E.Wijeysundera, S.Rajasekar, Performance of a compact spiral coil heat exchanger, Heat Recovery system & CHP, Vol-15,pp 457-
468,1995.
2. Swapnil Ahire, Purushottam shelke, B.Shinde, Fabrication and analysis of counter flow helical coil heat exchanger, IJETT, Vol-15, 2014.
3. Nasser Ghorbani,An experimental study of thermal performance of coil in shell heat exchanger,ICHMT,Vol-37,pp775-781,2010.
4. Yasuo Mori, Wataru Nakayama,study on forced convection heat transfer in curved pipes,IJHMT,Vol-10,pp 681-695,1967.
5. D.Q.Kern, Process heat transfer,pp 103,107,549,721,834,Mc Graw-Hill,1950.