Helical Coil Heat Exchanger

Thermal Design of Heat Exchangers ME 436 Fall 2007

Department of Mechanical Engineering Faculty Advisor: Dr. Abdelmessih Team Leader: Joel Parker Team Members: S. Cummings, M. Jorgenson

Table of Contents: Helical Coil Heat Exchanger Design Report The Problem Statement. ......................................................3 Acknowledgements .............................................................3 Background and Scop e...................................................... ..4 Preliminary Design............................ ..................................5 Preliminary Calculations for the Heat Exchanger................. ..6 Final Design................................................ .......................7 The Apparatus................................ ...............................8 -12 Flow Chart and Description .......................................... 13-14 Revised Calculations for the Heat Exchanger............. .........15 Results of the Test Run ....................... ..............................16 Final Calculations f or the Heat Exchanger...........................17 Discussion................................................................ ........18 Concluding Remarks................................................... ......19 Bibliography.....................................................................20 Nomenclature................................................................... 21

Helical Coil Heat Exchanger

Page 2

Appendices..........................................................................22-37 A-1) Budget......................................................................22 A-2) Laboratory Manual Sample .................................. ...23-29 A-3) Contribution of Team Membe rs...................................30 A-4) Experimental Data ................................................. ....31 A-5) Calculations by Hand............................................ 32-37 Preliminary............................................... ...........32-34 Revised............................................................. ......35 Final...................................................................36-37

Helical Coil Heat Exchanger

Page 3

Helical Coil Heat Exchanger Design Report : The Problem Statement : The thermal design of heat exchangers class received the challenge of designing and building a second heat exchanger apparatus for the thermal engineering laboratory. The heat exchanger apparatus currently in the thermal engineering laboratory is the 1 -4 * shell and tube heat exchanger designed and built in spring semester of 2002. The heat exchanger designed and built by the thermal design of heat exchangers class will give future mechanical engineering students an opportunity to work with a helical coil in a hands-on manner. In testing this apparatus, future students will be able to use their data to calculate Nusselt number, heat transfer coefficients and pressure drops for a helical coil.

Acknowledgements: The Design Team would like to thank the f ollowing people for their assistance in the completion of this project . First, we would like to thank the school for funding this design project. W e would like to extend a thank you to Ms. Hopie Lopez for her assistanc e with processing paperwork. W e must also thank Otto Jorgenson, as he has agreed to help make the plaque that we will proudly display on the apparatus; it is a donation from Jorgenson Manufacturing in Auburn.
*

1-4 means 1 shell with 4 tube passes

Helical Coil Heat Exchanger

Page 4

Background & Scope : Up until now, the students in heat transfer classes offered at Saint Martins University would not have been motivated to study helical coils and their related equations and correlations. Now however, they will not only be motivated to study these things, but there exists a means by which to apply them practically in a laboratory setting. By testing our apparatus, they will gain knowledge and experience that may benefit them in their careers. As a term project, a finned helical coil was presented to the team. The team was instructed to design a laboratory appar atus featuring the helical coil. Then it was built, tested and an experiment was created based on it. One of the main concerns for this experiment was safety based on the maturity levels of the students who will be testing the apparatus in future years . The goals of the experiment are as follows ; students should be able to calculate Nusselt number, calculate the heat transfer coefficient, calculate the friction factor, and calculate the pressure drop for the helical coil.

Helical Coil Heat Exchanger

Page 5

Preliminary Design: The original design for the apparatus involved the use of PVC tubing because it is light, inexpensive, resistant to corrosion and fouling, and easy to maintain. However, it was difficult to f ind fittings compatible with the thermocouples and the selected industrial gauges. The helical coil is housed in a five -gallon plastic bucket. The thermal characteristics of the plastic were considered as hot water is being used. The risks of deformations over time from loading on the lid of the bucket due to the weight of the helical coil were also considered. The choice was made to work with single -phase conditions for the heat exchanger apparatus. W ater was chosen as the working fluid for both the hot side and the cold side for safety reasons. It is a very safe fluid to work with. Touching it does not cause chemical burns although hot water can cause serious scalds and burns if caution is not taken to avoid contact. It will not stain clothing, nor will it destroy the actual fabric. It is not likely to cause illne ss if ingested and it is not harmful if the vapor is inhaled.

Helical Coil Heat Exchanger

Page 6

Preliminary Calculations for the Heat Exchanger: In this section , a summary of the calculations performed to size components needed to build the heat exchanger is presented . For further information, please refer to the Calculations section in the appendices (A-5). Table 1: Summary of Preliminary Calculations Parameter Amount Units Mass Flow Rate 2732.4 lb/hr Mean Velocity 32346.8 ft/hr Reynolds Number 53074 Prandtl Number 4.308 Dean Number 21667.4 Radius of Curvature 6.0 Nusselt Number Straight 276.94 Coil 475.09 Heat Transfer Coefficient Straight 2429.25 BTU/hr*sq. ft.*F Coil 4167.38 BTU/hr*sq. ft.*F Friction Factor Straight 0.005169 Coil 0.02038 Pressure Drop 3.407 PSI

Helical Coil Heat Exchanger

Page 7

Final Design: W e mounted the apparatus on a utility cart for the purpose of mobility and ease of storage. For the final design copper tubing and brass fittings were chosen. W e housed the helical coil in a five gallon plastic bucket . Furthermore, we took into consideration the thermal characteristics of the plastic considering we are using hot water. W e also considered t he risks of deformations over time from loading on the lid of the bucket due to the weight of the helical coil. For thermal data acquisition, we received two two -channeled Fluke meters. They process the electrical differential of the type -K thermocouples and display a temperature reading .

Figure 1: The Complete Apparatus in its Final State

Helical Coil Heat Exchanger

Page 8

The Apparatus: The following is a piecewise breakdown of the other main components that went into construct ion of the heat exchanger apparatus. The prices are noted where applicable. For further information on the budget please refer to appendix A -1.

The Helical Coil This is the main component in our apparatus. The helical coil is the focus of the heat exchanger; our apparatus will be unique in this aspect.

Figure 2: The Helical Coil

Figure 3: CAD drawing of the Helical Coil with Dimensions

Helical Coil Heat Exchanger

Page 9

The Hot W ater Heater: The hot water heater is a 3.85 gallon 110 VAC water heater. The hot water heater has a recovery rate of seven gallons per hour. It has a maximum pressure of 150 PSI and a temperature range of 65-145F. It was purchased at Home Depot for $182.30.

Figure 4: The Hot W ater Heater

Helical Coil Heat Exchanger

Page 10

The Pump: The pump is a one-half horsepower 110 VAC centrifugal pump made by Chicago Electric Power tools. It was purchased at Harbor Freight for $32. It is oversized for the design but due to budget constraints, options were limited. It has a maximum flow rate of 330 Gallons per hour and 115 feet of lift.

Figure 5: The Pump

Helical Coil Heat Exchanger

Page 11

The Volumetric Flow Me ters: The volumetric flow meters are from Cole -Palmer. One is a fifty-five to three hundred gallon per hour flow meter (figure 5a) for use with the cooling water and it cost $72. The other is a zero to sixty gallon per hour flow meter (figure 5b) for the hot water and it cost $110. Each Volumetric flow meter has a metering valve built into it. The volumetric flow meters were chosen based on initial flow calculations for each individual flow source.

Figures 6a (left) and 6b (right): Volumetric Flow Meters

Helical Coil Heat Exchanger

Page 12

Pressure Gauges The Differential Pressure Gauge: The differential pressure gauge (figure 7a) is also from Cole Palmer, although it is an Ashcroft product. It cost $100. It has a zero to fifteen pound per square inch differential chosen base d on early calculations. After running the experiment, it was discovered that the differential was too large. W ith a calculated pressure drop of 0.18 PSI a smaller differential gauge would work better. The Standard Pressure Gauges: These were procured at Grainger for $86.40 for the set of two. They are the solution to the initial option not functioning properly.

Figure 7a: The Differential Pressure Gauge

Figure 7b: The Set of Two Standard Pressure Gauges

Helical Coil Heat Exchanger

Page 13

Flow Chart and Description:

Figure 8: Flow Chart for the Final Design The figure above shows the flow paths of the hot water and coolant, which are the working fluids for the heat exchanger apparatus. The coolant, which is ordinary tap water, flows from the tap through a volumetric flow meter an d then into the heat exchanger that houses the coil. The water entering the system splits off into two flows, one to the hot water tank and one to the volumetric flow meter. The cold water enters the exchanger shell and discharges out the bottom of the e xchanger to a drain. The hot water runs directly through the helical coil into the reservoir, at the reservoir where it drains to the pump. The flow splits again to the reservoir and back to the water tank when valve 2 is closed creating a closed circuit. The configuration dependent flow s hown in green

Helical Coil Heat Exchanger

Page 14

in the above figure is dependent on whether valve 2 is open or closed. W hen valve 2 is open, it allows cold tap water to enter the hot water tank. W hen valve 2 is closed, it creates a closed circuit recycling the hot water that is pumping though the system.

Table 2: Valves Valve 1 Valve 2 Valve 3 Valve 4 Master Drain Valve Source Inlet to Hot Water Tank Pump Outlet Reservoir Overflow Valve

Helical Coil Heat Exchanger

Page 15

Revised Calculations for the Heat Exchan ger: In the table below is a summation of the results of calculating with improved measurements. These measurements were taken to aid in making the CAD drawing of the helical coil. The orange fill in the table below shows what parameters changed. For further information, please refer to the Calculations section in the appendices (A-5). Table 3: Summary of Revised Calculations Parameter Amount Units Mass Flow Rate 2732.4 lb/hr Mean Velocity 32346.8 ft/hr Reynolds Number 53074 Prandtl Number 4.308 Dean Number 18882.9 Radius of Curvature 7.9 Nusselt Number Straight 276.94 Coil 457.48 Heat Transfer Coefficient Straight 2429.25 BTU/hr*sq. ft.*F Coil 4012.90 BTU/hr*sq. ft.*F Friction Factor Straight 0.005169 Coil 0.02038 Pressure Drop 3.59 PSI

Helical Coil Heat Exchanger

Page 16

Results of the Test Run: A test run was completed on the apparatus. Once all of the components were in place, the system was checked thoroughly for leaks. After fixing the leaks, the apparatus was prepared for testing. The test run commenced with the apparatus being tested under laboratory conditions. Data was recorded every five minutes until the apparatus reached steady state. The hot temperatures fell as expected; the cold temperatures seemed to be more unpredictable in one instance rising six degrees in five minutes and then on the next reading falling three degrees. The apparatus took 150 minutes to reach steady state, which can vary based on operating conditions. Readings were taken until the three -hour mark; however, t he data became inconsistent, so a steady state set was determined based on proximity of the readings. The raw data is included in the appendices for reference (A -4). Full n umerical results are presented in the appendices (A -5) and a summation is given in the section below. The apparatus is in working order and ready for use in the laboratory with a few small exceptions (see discussion).

Helical Coil Heat Exchanger

Page 17

Final Calculations f or the Heat Exchanger: In the tables below, we present our initial conditions and a summation of calculations . W e computed these calculations after testing the apparatus u nder laboratory conditions. Table 4: Initial Conditions T-hot in 93.0 T-hot out 84.0 T-cold in 55.5 T-cold out 61.5 (dV/dt)hw (dV/dt)cw P-drop * DNF 58 52

Table 5: Summary of Final Calculations Parameter Amount Units Mass Flow Rate 481.77 lb/hr Mean Velocity 5685.5 ft/hr Reynolds Number 7908 Prandtl Number 5.2 Dean Number 2814 Radius of Curvature 7.9 Nusselt Number Straight 182.6 Coil 292.5 Heat Transfer Coefficient Straight 1569 BTU/hr*sq. ft.*F Coil 2153.00 BTU/hr*sq. ft.*F Friction Factor Straight 0.008414 Coil 0.03286 Pressure Drop 0.18 PSI

Did Not Function Page 18

Helical Coil Heat Exchanger

Discussion: These problems were encountered during the course of working on the design. A reservoir bucket cracked during the building process and a replacement was purchased . The apparatus sprung a couple of leaks during the first and second trials. The hot water heater had to be repositioned , as it would not function properly in the previo us position. After testing the apparatus, some possible modifications to the system are suggested. One such suggestion is to procure a b etter pressure gauge that fits our final design , one that can detect a pressure drop of 0.18 PSI. This problem was so lved by using two standard pressure gauges one for the inlet and one for the outlet. Another suggestion is at some point replacing the probe thermometer with a thermocouple to obtain the cold entrance temperature more accurately. The thermocouple has bee n procured and has been mounted and functioned properly . The calculations went through multiple runs, as new information was discovered that changed what the results calculated previously. A majority of the needed information for the calculations was found in textbooks for previous courses or curre nt courses. The Konakov correlation for friction factor for the helical tube was found in volume two of the Heat Exchanger Design Handbook.

Helical Coil Heat Exchanger

Page 19

Concluding Remarks: The future students will benef it from the hand s-on study of the helical coil heat exchanger apparatus. This apparatus will be a valuable addition to the thermal engineering laboratory for years to come.

Helical Coil Heat Exchanger

Page 20

Bibliography: Heat Exchanger Design Handbook, Begell House, 2002 Ed. Volume 2 Section 5 Equation 42 Heat Exchangers: Selection, Rating and Thermal Design, Kakac & Liu 2 n d Ed. Pgs 95 and 119 Fundamentals of Fluid Mechanics, Munson et . al. 5 t h Ed. Appendix B Table 1 Fundamentals of Heat and Mass Transfer, Incropera, DeW it t, Bergman & Lavine, 6 t h Ed. Page 949,Table A.6 and Conversion Factors, End pages Thermal Engineering Laboratory Manual, Abdelmessih, 6 t h Ed. Heat Exchanger, Chapter 17, Pages 58 -63 Thermodynamics: An Engineering Approach, Boles and Cengel, 5 t h Ed. Page 938 Table A-3E

Helical Coil Heat Exchanger

Page 21

Nomenclature: Roman Symbols: D= Coil diameter, inches d= Tube diameter, inches (dV/dt)cw=Cold W ater Volumetric flow rate, Gallons per Hour (dV/dt)hw= Hot W ater Volumetric flow rate, Gallons per Hour LL= long straight leg of t he coil, inches SL= short straight leg of the coil, inches P-drop= pressure drop , PSI

Greek Symbols: = curvature ratio (D/d)

Subscripts: c= Coiled tube property cw= cold water hw= hot water i= inner dimension o= Outer dimension s= Straight tube property

Helical Coil Heat Exchanger

Page 22

Appendix A-1 Budget: Our initial budget allotted was $400. W e ended up spending approximate ly $830, which was definitely in excess of our initial budget. The approximated amounts were paid in cash and the receipts have been submitted to the secretary of the Engineering department. The exact budget is difficult to compute at this time, as some of the receipts are not in the teams possession. Table 6: List of Expenditures
Part Ariston Water Heater Galvanized Steel Bucket Clearwater Pump Differential Pressure Gauge Volumetric Flow meter (55-300 GPH) Volumetric Flow meter (0-60 GPH) Tax from Cole-Palmer purchases Copper tubing Blue Bucket Ball Valves Compression Fit Spigot Utility Cart Clear 1/16th inch plexiglass Thermocouple shield Pressure Gauge Sundry Fittings and Miscellany Source Home Depot Lowe's Harbor Freight Cole-Palmer Cole-Palmer Cole-Palmer Cole-Palmer Lowe's Lowe's Lowe's Lowe's Harbor Freight DK Boos Glass Omega Grainger Various Unit Cost $ 182.30 $ 8.00 $ 32.00 $ 100.00 $ 72.00 $ 110.00 $ 23.69 $ 17.00 $ 4.00 $ 7.00 $ 8.00 $ 43.35 $ 5.42 $ 22.50 $ 43.20 Quantity 1 1 1 1 1 1 1 2 1 4 1 1 1 1 2 Total Total Cost $ 182.30 $ 8.00 $ 32.00 $ 100.00 $ 72.00 $ 110.00 $ 23.69 $ 42.00 $ 4.00 $ 28.00 $ 8.00 $ 43.35 $ 5.42 $ 22.50 $ 86.40 $ 174.66 $ 942.32

Table 7: List of Donations

Part Duct Tape Commemorative Plaque White Bucket Surge Protector Helical Coil Source Peter Jorgenson Jorgenson Manufacturing Saint Martin's University Maintenance Saint Martin's University Thermal Engineering Laboratory

Helical Coil Heat Exchanger

Page 23

Appendix A-2 (Draft) Chapter ___ Helical Coil Heat Exchanger Experiment

Forew ord: In fall semester of 2007, Thermal Design of Heat Exchangers class (Jorgscumpark Industries) cr eated this laboratory experiment for not only your enlightenment but also your entertainment. W e would like to take this opportunity to remind you to keep safety in mind as you work through this experiment. So, remember have fun and be safe.

Problem Sta tement: The Heat Transfer Company is seeking your participation in a program for the investigation of the Helical Coil Heat Exchanger designed and built by Jorgscumpark Industries in the fall of 2007. They donated their time creating this apparatus for the Thermal Engineering Laboratory as well as for the generations of future employees of the Heat Transfer Company. It is now up to you to test it.

Purpose: From your experimental data, you should be able to make various calculations. You can calculate Nusselt number, heat transfer coefficient, and pressure drops for the helical coil. You should be able to find all the information you require in your Heat Transfer textbook or within this laboratory manual. If you should need any other information , you may perform a literature search for it and cite the sources you used.

Helical Coil Heat Exchanger

Page 24

Equipment: Gauges: Three Thermocouples and a probe thermometer Two Volumetric flow meters - Cole Palmer One Differential pressure meter - Ashcroft

Pump: Clearwater Pump - Chicago Electr ic Power tools Model #01479

Buckets: Five gallon white bucket - housing for the coil Three-gallon bucket- overflow reservoir and trapped air removal method

Hot W ater Heater: Four-gallon water heater- Ariston - It is imperative that you avoid getting excess water on the hot water heater.

Data Acquisition: 2 two channeled Fluke meters

Miscellany: A mop and mop bucket - for any spills and the leaky fresh water supply Rags or paper towels - also for spillage Reservoir Cover

Helical Coil Heat Exchanger

Page 25

Dimensions of the Helical Coil: Figure 1: Dimensions of the Helical Coil

Experimental Procedure: Experimental Phase: 1. First, as to not damage the circuit breaker, turn off any equipment you are not using for this laboratory exercise. 2. Perform a safety check on t he apparatus. Check the device for exposed wires and other such dangers. This is also a good time to check the connections on the apparatus. Make sure that all valves are closed. Plug in the surge protector.

Helical Coil Heat Exchanger

Page 26

3. If the pump has not been used in more than five days, remove the cover and turn the fan with a screwdriver.

4. Connect the source hose to the source spigot, making sure that the spigot is closed. Place the discharge hose into the floor drain. 5. Open valve 2 and Turn on source water. Allow the water level to rise to a point where the helical coil is fully submerged before. Use the view port on the heat exchanger lid to verify, visually, the water level. W hile the heat exchanger is filling up, turn on the hot water heater. 6. Once desired temperature is reached, open the metering valve on hot water volumetric flow meter and begin filling the reservoir approximately half way. 7. Note: Make sure that the valves are opened in the proper order specified. 8. Close valve 2 9. Open valve 3 and turn on pump by plugging into the surge protector (Make sure water in reservoir is at least half way full as failing to do so will burn out the pump). This will

Helical Coil Heat Exchanger

Page 27

create a closed circuit for the hot water. 10. Adjust hot water flow rate as

desired. 11. Adjust valve 1 and cold water

flow rate (via the volumetric flow meter) such that the cold water entering the heat exchanger is in synch with the cold water exiting out the discharge. 12. Connect the three

thermocouples to the Fluke meters. Make note of thermocouple orientation. 13. Insert the type -K temperature

probe into the hole on the top of the heat exchanger until it makes contact with the cold-water inlet flow. Then connect it to the Fluke meter port. 14. Begin taking readings at

desired intervals until steady state conditions. 15. Keep an eye on water level in

the reservoir, if overflow is imminent open valve 4 to discharge.

Table 1: Note on valves: Valve 1 Valve 2 Valve 3 Valve 4 Master Drain Valve Source Inlet to Hot Water Tank Pump Outlet Reservoir Overflow Valve

Helical Coil Heat Exchanger

Page 28

Post Experimental Phase: 1. Secure the apparatus; close all valves unplug the pump, hot water heater and anything else you plugged in. Also, please leave the thermal engineering lab as clean as you found it. 2. From the volumetric flow rates, calculate mass flow rates. Do this with your steady state data 3. Predict the fouling factors for the apparatus. 4. Begin your calculations for the following a. Nusselt numbers b. Heat transfer coefficients c. Pressure drops

Useful Correlations: Petukhovs Correlation for Nusselt number (2) Nu s =((f/2)*Re*Pr)/(1.07+12.7*(f/2)^(1/2)*(Pr^(2/3) -1)) W here f=(1.58*ln(Re)-3.28)^-2 Schmidts Correlation for Nusselt number (2) Nu c =(1.0+3.6*(1 -(1/ ))*(1/ )^0.8)* Nu s Konakovs Correlation for friction factor (1) f=(1.8*log(Re)-1.5)^-2

Helical Coil Heat Exchanger

Page 29

References: (1) Heat Exchanger Design Handbook, Begell House, 2002 Ed. (2) Heat Exchangers: Selection, Rating and Thermal Design, Kakac & Liu 2 n d Ed. (3) Thermal En gineering Laboratory Manual, Abdelmessih, 6 t h Ed.

Helical Coil Heat Exchanger

Page 30

Appendix A-3: Contribution of Team Members: J. Parker: Team Leader & Treasurer Overall design and construction of heat exchanger apparatus Development of experimental procedure Maintained budget records General research

S. Cummings: Production Assistant & Draftsman Construction of thermocouple units Computer Drafting of flow chart and helical coil Assisted in design and construction of the apparatus Photography General research

M. Jorgenson: Secretary & Principal Photographer Calculations Correlation research Photography Compiled final report Scholars Day Liaison

Helical Coil Heat Exchanger

Page 31

Appendix A-4:
Ex per im en t al D a ta V ol um etr ic f l o w r a tes : Ho t: 5 8 G PH T abl e 8 : Da t a S pr ea ds he e t Time (sec) time (min) T-hot in T-hot out T-cold in T-cold out 0 0 93.9 84.0 55.5 61.5 300 5 93.7 83.9 54.5 61.5 600 10 93.8 84.1 53.4 61.7 900 15 93.5 83.9 53.1 61.6 1200 20 93.2 83.7 53.4 61.6 1500 25 93.3 83.7 54.0 61.2 1800 30 93.1 83.5 52.5 61.2 2100 35 93.3 83.6 53.3 61.4 2400 40 93.3 83.5 53.4 61.6 2700 45 92.9 83.1 54.3 61.9 3000 50 93.1 83.3 54.3 61.7 3300 55 92.8 83.1 54.5 61.5 3600 60 92.9 83.1 54.9 61.6 3900 65 92.6 82.7 55.2 61.9 4200 70 92.8 82.9 54.0 61.9 4500 75 92.5 82.8 54.5 61.5 4800 80 92.7 82.8 55.4 61.6 5100 85 92.7 82.9 56.4 61.5 5400 90 92.7 82.7 56.9 61.6 5700 95 92.6 83.1 51.5 61.1 6000 100 92.7 83.3 51.8 61.4 6300 105 93.0 82.8 57.0 61.7 6600 110 92.7 82.7 55.3 62.3 6900 115 92.5 82.9 51.7 61.4 7200 120 92.5 82.9 51.9 61.4 7500 125 92.7 82.9 51.9 61.4 7800 130 92.9 83.0 51.9 61.5 8100 135 92.8 83.0 51.4 61.1 8400 140 92.8 83.1 51.6 61.4 8700 145 92.9 83.3 51.5 61.4 9000 150 92.9 83.3 51.5 61.4 9300 155 93.1 83.7 51.5 60.9 9600 160 93.3 83.6 51.5 61.7 9900 165 93.4 83.4 51.5 61.7 10200 170 93.3 83.3 51.5 61.7 10500 175 93.1 82.7 51.5 61.9 10800 180 92.9 82.5 51.5 61.9 T he ye l l o w h ig h l ig h t i n d ic a tes t h e v a lu es us e d f or s t e ad y s t a te c a lc u la t io ns . C o ld : 52 G PH

Helical Coil Heat Exchanger

Page 32