King Abdulaziz University

Mechanical Engineering Department

MEP 460
Heat Exchanger Design

Double pipe heat

Exchanger

March 2018
 Ch. 7 Double pipe heat exchangers

1-Introduction
2-Advantages and disadvantages of double pipe HX
3-Double pipe HX geometry
4-Unfinned outside surface of inner pipe
5-Example 7.1
6-Finned outer surface of the inner pipe
7-Example 7.2
8-Series & parallel combination of hairpins HX
9-Total pressure drop in double pipe HX
1-Introduction
Hairpin double pipe heat exchangers
1-Introduction
Finned and un-finned double pipe heat exchangers
Multi tube double pipe heat exchangers
 2-Advantages and disadvantages of double pipe
heat exchanges

advantages

Good for sensible heating or cooling

Up to 50 2 heat transfer area
Good for one or two fluids at high pressure
Can be used at severe fouling condition since it can easily be
cleaned
Can achieve pure parallel or counter flow arrangement
U tube or hairpin heat exchanger can handle thermal expansion
Extra units can be easily added

Disadvantages

Bulky
Expensive
 3-Double pipe geometry

𝜋
Cross section area for annulus flow 𝐴𝑐 = 𝐷𝑖2 − 𝑑𝑜 ^2
4
 Hydraulic diameter for heat transfer calculations and
pressure drop calculations for annulus flow
De for heat transfer calculations

By definition the hydraulic 4 𝑚𝑖𝑛. 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎

𝐷ℎ =
diameter 𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑟𝑒𝑚𝑖𝑡𝑒𝑟
Perimeter for heat transfer
calculations 𝑃ℎ = 𝜋𝑑𝑜

Hydraulic diameter for 4𝐴𝑐 𝜋

heat transfer calculations 𝐷𝑒 = 𝐴𝑐 = 𝐷𝑖2 − 𝑑𝑜2
𝑃ℎ 4

4(𝜋 𝐷𝑖2 4 − 𝜋𝑑𝑜2 4) 𝐷𝑖2 − 𝑑𝑜2 ℎ𝐷𝑒

𝐷𝑒 = = 𝑁𝑢 =
𝜋𝑑𝑜 𝑑𝑜 𝑘
𝑚𝑎 𝜌𝑎 𝑉𝑎 𝐷ℎ
Annulus flow velocity 𝑉𝑎 = 𝑅𝑒 𝑎 =
𝜌𝑎 𝐴𝑐 𝜇𝑎
 Hydraulic diameter for heat transfer calculations and
pressure drop calculations for annulus flow
Dh for pressure drop calculations

Perimeter for pressure drop 𝑃𝑤 = 𝜋(𝐷𝑖 + 𝑑𝑜 )

calculations
Cross section area 𝐴𝑐 = (𝜋 4)(𝐷𝑖2 − 𝑑𝑜2 )

Hydraulic diameter for pressure 4𝐴𝑐

calculations 𝐷ℎ =
𝑃𝑤

4(𝜋𝐷𝑖2 4 − 𝜋𝑑𝑜2 4)
𝐷ℎ = = 𝐷𝑖 − 𝑑𝑜
𝜋(𝐷𝑖 + 𝑑𝑜 )

𝜌𝑎 𝑉𝑎 𝐷ℎ
𝑅𝑒𝐷ℎ =
𝜇𝑎
 Pressure drop calculations
2
2𝐿 𝑢𝑚 2𝐿 𝐺 2
Inside the tubes Δ𝑝𝑡 = 𝑓 𝜌 𝑁ℎ𝑝 = 𝑓 𝑁ℎ𝑝
𝑑𝑖 2 𝑑𝑖 2𝜌
Δ𝑝𝑡 𝑚𝑡
𝑃𝑡 =
Pumping power 𝜂𝑝 𝜌

2𝐿 𝑢𝑎2
Δ𝑃𝑎 = 𝑓 𝜌 𝑁 Assuming the length of
Flow in the annulus 𝐷ℎ 2 ℎ𝑝 hairpin HX to be L

Δ𝑝𝑎 𝑚𝑎
Pumping power 𝑃𝑎 =
𝜂𝑝 𝜌

Nhp is the number of hairpins HX

Example 7.1
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
Example 7.1 continue
 Kakac used expression for finding the heat transfer
coefficient for both inside the pipe and in the annulus
See Ch. 3 & 4

Or in log form

For hairpin of length L.

Remember f=fKakac/4
Incropera Expression for turbulent flow heat
transfer coefficient
 6-Finned outer surface of the inner pipe

Hf fin height
 Fin thickness
Nf no of fins per tube
Nt no of tubes
 Hairpin Heat exchanger with multi-tube finned inner pipe

The wetted perimeter for

hydraulic diameter

𝑃𝑤 = 𝜋 𝐷𝑖 + 𝑑𝑜 𝑁𝑡 + 2𝐻𝑓 𝑁𝑓 𝑁𝑡

For calculating the heat

transfer equivalent diameter

𝑃ℎ = 𝜋𝑑𝑜 + 2𝐻𝑓 𝑁𝑓 𝑁𝑡 Symbol meaning

Nt Number of tubes
Cross section flow area Nf Number of fins/tube
𝜋 Hf Fin height
𝐴𝑐 = 𝐷𝑖2 − 𝑑𝑜2 𝑁𝑡 − 𝛿𝐻𝑓 𝑁𝑡 𝑁𝑓
4
 Fin thickness
4𝐴𝑐 4𝐴𝑐 L Heat exchanger length
𝐷𝑒 = 𝐷ℎ =
𝑃ℎ 𝑃𝑤
 6-Finned outer surface of the inner pipe
Area of the un-finned part 𝐴𝑢 = 2𝑁𝑡 (𝜋𝑑𝑜 𝐿 − 𝑁𝑓 𝐿𝛿)
𝐴𝑓 = 2𝑁𝑡 𝑁𝑓 𝐿(2𝐻𝑓 + 𝛿)
Area of the fins

Total area =Un-finned area +

finned area

𝐴𝑡 = 𝐴𝑢 + 𝐴𝑓 = 2𝑁𝑡 𝐿(𝜋𝑑𝑜 + 2𝑁𝑓 𝐻𝑓 )

Surface overall efficiency

𝐴𝑓
𝜂𝑜 = 1 − 1 − 𝜂𝑓
𝐴𝑡

Efficiency for straight fin

tanh(𝑚𝐻𝑓 ) 2ℎ
𝑚=
𝜂𝑓 = 𝛿𝑘𝑓
𝑚𝐻𝑓
 Clean and fouled overall heat transfer coefficient
Finned double pipe
1 1 𝑅𝑓𝑖 𝑅𝑓𝑜 1
= + + 𝑅𝑤 + +
𝑈𝑜𝑓 𝐴𝑡 ℎ𝑖 𝐴𝑖 𝐴𝑖 𝐴𝑡 𝜂𝑜 ℎ𝑜 𝐴𝑡 𝜂𝑜
1 1 𝑅𝑓𝑖 𝑅𝑓𝑜 1
= + + 𝐴𝑡 𝑅𝑤 + +
𝑈𝑜𝑓 ℎ𝑖 (𝐴𝑖 𝐴𝑡 ) (𝐴𝑖 𝐴𝑡 ) 𝜂𝑜 ℎ𝑜 𝜂𝑜
ln(𝑑𝑜 𝑑𝑖 )
𝑅𝑤 =
𝐴𝑡 = 𝐴𝑢 + 𝐴𝑓 = 2𝑁𝑡 𝐿(𝜋𝑑𝑜 + 2𝑁𝑓 𝐻𝑓 ) 2𝜋𝑘𝐿

𝐴𝑓
𝐴𝑖 = 𝜋𝑑𝑖 (2𝐿) 𝜂𝑜 = 1 − 1 − 𝜂𝑓
𝐴𝑡
You may assume a length for the hairpin HX
and then find the number hairpins required.
tanh(𝑚𝐻𝑓 )
1 1 1 𝜂𝑓 =
For clean surface = + 𝐴𝑡 𝑅𝑤 + 𝑚𝐻𝑓
𝑈𝑐 ℎ𝑖 (𝐴𝑖 𝐴𝑡 ) ℎ𝑜 𝜂𝑜
𝑈𝑜𝑓 2ℎ
Cleanliness factor CF 𝐶𝐹 =
𝑈𝑐 𝑚=
𝛿𝑘𝑓
Percentage Over 𝑂𝑆 = 100𝑈𝑐 𝑅𝑓𝑡
1 − 𝐶𝐹
where 𝑅𝑓𝑡 =
surface OS 𝑈𝑐 𝐶𝐹
Ch. 3 correlations for convective heat transfer
coefficients (Laminar internal flows)
Ch. 3 correlations for
convective heat
transfer coefficients
(Turbulent
internal flows)
Incopera 7th ed.
Correlations for
convective heat
transfer
coefficient for
internal flows
Incropera, internal turbulent flow
Incropera-Laminar flow

𝐷
𝐺𝑧 = 𝐺𝑟𝑎𝑒𝑡𝑧 𝑛𝑢𝑚𝑏𝑒𝑟 = 𝑅𝑒 𝑃𝑟
𝑥
Internal laminar flow-Kakac used correlation

𝑃𝑒𝑐𝑙𝑒𝑡 𝑁𝑢𝑚𝑏𝑒𝑟 𝑃𝑒 = 𝑅𝑒 𝑃𝑟
Example on Finned double pipe heat
exchangers
 Tci=20  C
Tco=30  C

m_dot=3 kg/s
Thi=65 C
Tho=55  C
Example 7.2 continue

See table 9.2 for detailed

information about the tubes
Example 7.2 continue

Procedure:
1-Since all 4 temperatures are known. One can get the
main fluid properties at the mean value. The main
properties are:
Cp, , k, , and Pr
2-Since mh is known, calculate the heat load q
3-From 2 you can calculate the mass flow rate mc (in
the inner tube)
4-Calculate the cross sectional area for the flow inside
the pipe and in the annulus, and the two velocities
5-Calculate the hydraulic diameter for pressure and
heat transfer calculation (i.e. Dh, and De)
6-Caculate f & Re for both flows and Nu
7-Caculate hi and ho
8-Estimate Rfi and Rfo based on fluid type and tables in
Sea water(Cold)
Ch. 6 (Fouling)
9-Calculate Uof and Uc Tci=20  C
10-Find CF and OS Oil (hot) Tco=30  C
m_dot=3 kg/s
Thi=65  C
Tho=55  C
Example 7.2 continue

Inner Tube, Sea Water

Sea water(Cold)
Tci=20  C
Oil (hot) Tco=30  C
m_dot=3 kg/s
Thi=65  C
Tho=55  C
Example 7.2 continue
Example 7.2 continue
Example 7.2 continue

Laminar
Example 7.2 continue
Example 7.2 continue

Fouling factors and overall heat transfer

coefficients
Should be Table 6.5 & 6.11
Fouling factors (Kakac Ch. 6)
Fouling factors (Kakac Ch. 6)

Sea water and brackish

water are missing from
this table
http://www.engineeringpage.com/technology/
thermal/fouling_factors.html
Example 7.2 continue
Example 7.2 continue
Example 7.2 continue
8-Series-parallel arrangement of double pipe heat exchangers
8-Series-parallel arrangement of double pipe heat exchangers

Hairpin can be connected in

series one after the other to
get pure counter or pure
parallel arrangement

But this may cause high

pressure drop and
excessive pumping power,
therefore hairpin can be
connected in parallel
/series combinations.

A correction factor for the LMTD must then apply

8-Series-parallel arrangement of double pipe heat exchangers

Parallel series combinations

8-Series-parallel arrangement of double pipe heat exchangers
The LMTD for double pipe HX with combination of series
and parallel arrangement must be modified as follows:
𝑄 == 𝑈𝐴 Δ𝑇𝑚 = 𝑈𝐴𝑆(𝑇ℎ𝑖 − 𝑇𝑐𝑖 )
Where S is given by:
1 − 𝑃1
For one series hot fluid and n1 𝑆= 1 𝑛1
𝑛1 𝑅1 𝑅1 − 1 1 1
parallel cold stream
𝑅1 − 1 𝑙𝑛 𝑅1 𝑃1 + 𝑅
1

𝑇ℎ2 − 𝑇𝑐1 𝑇ℎ1 − 𝑇ℎ2

𝑃1 = 𝑅1 =
𝑇ℎ𝑖 − 𝑇𝑐1 𝑛1 (𝑇𝑐2 − 𝑇𝑐1 )

1 − 𝑃2
For one-series cold stream and 𝑆= 1 𝑛2
𝑛2 1
n2 parallel hot streams
1 − 𝑅2 𝑙𝑛 1 − 𝑅2 + 𝑅2
𝑃2

𝑇ℎ1 − 𝑇𝑐2 𝑛2 (𝑇ℎ1 − 𝑇ℎ2 )

𝑃2 = 𝑅2 =
𝑇ℎ1 − 𝑇𝑐1 𝑇𝑐2 − 𝑇𝑐1
 9-Total pressure drop

All pressure losses must be taken into account for calculating the total
pressure losses in heat exchanger. These sources of pressure drop must be
considered

1-Friction or major losses due to wall friction

2-Minor losses such as pressure drop in inlet and
outlet nozzles
3-Pressure drop due elevation difference between
inlet and outlet
4-Pressure drop due momentum change

2
2
2𝐿 𝑢𝑚 𝑢𝑚
Δ𝑃𝑓 = 𝑓 𝜌 𝑁 Δ𝑃𝑛 = 𝐾𝑐 𝜌
1 𝐷 2 ℎ𝑝 2 2

2
11
4 Δ𝑃𝑚 = 𝐺 ( − )
3 Δ𝑃 = 𝜌𝑔 Δ𝐻 𝜌𝑜𝑢𝑡 𝜌𝑖𝑛