ME495

Lab 3: Tubular Heat Exchanger

Group D:
David Elting

Christopher Goulet

Gerardo Espinoza

Rodolfo Gonzalez

Professor Sam Kassegne

11-21-07

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 Table of Contents

1. Title Page...............................................................................................................1

2. Table of Contents...................................................................................................2

3. Objective of the Experiment (David Elting)........................................................3-4

4. Equipment (Rudy Gonzalez)................................................................................5-6

5. Experimental Procedure (Gerardo Espinoza).......................................................7-8

6. Experimental Results (Christopher Goulet).......................................................9-12

7. Discussion of Results (Christopher Goulet).....................................................13-14

8. Lab Guide Questions (Christopher Goulet) .........................................................15

9. Conclusion (David Elting)....................................................................................16

10. References (David Elting).....................................................................................17

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 Objective
The objective of this laboratory exercise is to familiarize the student with heat transfer in
heat exchangers. The student will also learn about the different transducers used to detect
and measure the physical properties used when calculating the heat transfer between the
hot and cold media in the heat exchanger. A HT30X Heat Exchanger Unit and HT31
Tubular (tube-in-tube) Heat Exchanger are used for this laboratory. The HT30X and
HT31 are test devices created for use in physics and engineering laboratories by Armfield
Limited, Ringwald, Hampshire England.

Introduction
The tubular heat exchanger is the simplest form of heat exchanger. It consists of two
concentric (coaxial) tubes. The inner metal tube carries a hot fluid and the outer acrylic
annulus carries the cold fluid, such that the inner tube’s outer surface is in direct contact
with the cold fluid. Any temperature difference across the metal tube wall will result in
the transfer of heat between the two fluid streams. The hot water flowing through the
inner tube will be cooled and the cold water flowing through the outer annulus will be
heated. A thermocouple is placed at the center location along the heat exchanger length
and at entrance and exit of both the hot and cold fluid streams. The temperature of the hot
fluid and the flow rate of the cold and hot streams are controlled by the student during
each exercise. Tubular heat exchangers may be configured where the flow of the two
T

δQ = h U ( Tc - T ) d A
T h , i n
T h

∆T h T h , o u t

∆T 1
∆T ∆T 2

∆T T c , o u t
c

T
T c , i n
c

1 2
A
dA
C o l d F l u i d
dA T c , o u t

H o t F l u i d H o t F l u i d
T h , i n T h , o u t

C o l d F l u i d
T c , in
fluids enter at the same side of the exchanger and flow in the same direction (parallel
flow) or made to flow in opposite directions (counter flow).

Figure1: Parallel flow heat exchanger

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 T

T h , i n

T h

T h , o u t

∆T T c , o u t
T c

T c , i n

A
dA C o l d F l u i d
T c , in

H o t F l u i d H o t F l u i d
T h , i n T h , o u t

C o l d F l u i d
T c , o u t

Figure 2: Counter flow heat exchanger

Counter flow is preferred, as the difference in temperature between the hot and cold
fluids is relatively constant along the full length of the heat exchanger. This is a benefit
because extreme differences in temperature are eliminated that can thermally stress the
heat exchanger material.
The following relationships will be used in this lab exercise.
Mass flow rate: mdot = Volume flow rate (Vdot) × density of the fluid (ρ )
Heat power: Q = mdot × cp × ∆ T
cp ∴ constant specific heat
Heat emitted from the hot fluid: Qe = mhcp,h(T1 − T3)
Heat absorbed by the cold fluid: Qa = mccp,c(T6 − T4)
The temperature efficiency (countercurrent flow) for hot fluid: η h = [(T1 − T3)/(T1 − T4)]
× 100%
The temperature efficiency (countercurrent flow) for cold fluid: η c = [(T6 − Τ 4)/(T1 − T4)
] × 100%
The mean temperature efficiency: η c = (η h − η c)/2 %
Overall Efficiency for the system: η = (Qa / Qe) × 100%
Theoretically, Qe = Qa but do not due to heat loss given by Qf = Qe − Qa

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 Equipment

Fig.3 HT31 Tubular Heat Exchanger Fig.4 HT30X Heat Exchanger service unit

• HT31 Tubular Heat Exchanger

-Height: 0.16m
-Width: 0.51m
-Depth: 0.39m
-Volume 0.05m3
-Gross weight 4kg
-Max heat transfer area: 0.02m2,0.08m2
-Maximum 6 temperature measurement points at a time:
1 Hot fluid inlet
2 Hot fluid mid-position
3 Hot fluid outlets
4 Cold fluid inlet
5 Cold fluid- mid position
6 Cold fluid outlet
7 Hot fluid internal positions
8 Cold fluid internal positions

• HT30X Heat Exchanger service unit

- Volume: 0.33m³
-Gross weight: 33kg
1. Cold water supply stream
2. Hot water supply stream

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 3. Hot water vessel with an electrical heater
4. Gear pump
5. Variable flow valves
6. Pressure regulator
7. Flowmeters calibrated from 0.2 to 5 L/min
8. Digital displays
9. Conditioning circuit outlets for the Heat Exchanger
10. Drain
• Lab table
• Latex gloves

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 Procedure

Using the lab manual as a guide to do the experiment, the lab was started by

mounting the heat exchanger to the HT30X heat exchanger service unit. Then all the

sensors were connected to the main console in order to record the temperature and set the

hot and cold water flow rates. Also the hoses were connected to flow water through the

heat exchanger and the heater. Before the experiment was started, the hot and cold water

circuits had to be primed in order to remove any air bubbles that could give false

readings.

The priming was done by connecting the heat exchanger hot water inlet to the

heat exchanger cold water outlet. Next, the heat exchanger hot water outlet was

connected to the HT30X hot water inlet. The hot water bypass valve had to be closed, and

the cold water pressure regulator was set to a minimum setting by pulling the control

knob out (to the right) and turning full counter clockwise. Then the cold water flow

control valve was fully opened and gradually adjusted the cold water pressure regulator

control knob clockwise until water was seen flowing through the hot water circuit

flexible tubing and into the clear plastic priming vessel. When the priming vessel was full

and there were no more air bubbles in the lines, the cold water flow control valve was

closed. Afterwards the tube from the heat exchanger cold water outlet was disconnected

and reconnected to the HT30X hot water outlet. The hot water circulating pump and

heaters were switched on. Finally the hot water bypass valve was opened and closed

several times until all of the air bubbles were expelled from the tubing.

After the hot and cold water circuits were primed, the cold water pressure had to

be set. First the cold water pressure regulator was set by connecting the heat exchanger

cold water inlet to the HT30X cold water outlet. Then the heat exchanger cold water

outlet tube was routed to the center drain area of the HT30X. Next the flow indicator

switch on the main console was set to Fcold and the cold water flow control valve was

fully opened. The cold water pressure regulator control knob was adjusted until the flow

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display on the main console indicated 3 liters/min. Finally, the cold water pressure

regulator control knob was locked into position by pressing to the left on the tip of the

knob and then the cold water flow control valve was closed. Now the experiment was

ready to begin.

The experiment began by connecting the fluid supply tubing so the flow was

countercurrent. All the thermocouple plugs were connected to their respective sockets in

the console display. Then 45°C was added to the reading and the temperature controller

was set to this value by momentarily pressing the setpoint key. Next the increase key or

decrease key was pressed until the desired setting was indicated. The flow indicator

switch on the main console was set to Fcold and then the cold water control valve Vcold was

adjusted to read 1 liter/min. The flow indicator switch was set to Fhot and then the hot

water control valve Vhot was adjusted to read 3 liter/min. The heat exchanger was allowed

to stabilize by monitoring the temperatures using the console display. When the

temperatures were stable, the thermocouple selector knob was rotated to different

temperatures in order to record the values for T1, T2, T3, T4, T5, T6, Fcold, and Fhot. Next

the flow indicator switch was set to Fcold and the cold water control valve Vcold was

adjusted to read 2 liter/min. After the heat exchanger was stabilized, the new values from

the sensor outputs were recorded. Finally the flow indicator switch was set to Fcold and the

cold water control valve Vcold was adjusted to read 3 liter/min. After the heat exchanger

was stabilized, the new values from the sensor outputs were recorded.

Once all the values were recorded, it was time to clean up the area. The heat

exchanger was removed from the HT30X heat exchanger service unit and put away in its

rightful location. The HT30X was shut down and disconnected and returned to its

location. Finally, all the water that was spilled on the units and on the floor was picked up

in order to keep the area safe and clean.

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 Experimental Results
1. Calculate the following for each set of data:
Sample Calculation
Experiment 1
a. The heat emitted from the hot fluid
kg  kJ 
(68 .6 C − 64 .9 C ) = 0.763 kW

 hot c p , hot (T3 − T1 ) =  0.0493
Q hot = m 
 4.18   

 s  kg ⋅
C 

b. The heat absorbed from the cold fluid

kg  kJ 

Q 

cold = m cold c p , cold (T4 − T6 ) =  0.0169
s
 (
 4.18 kg ⋅ C  )
 40 .4 C − 23 .1 C = 1.22 kW
 

  

c. Mass flow rate for the hot fluid

 m3  kg  kg
 hot = Vhot ρ hot =  5.03e − 5
m  979 3  = 0.0493
 s  m  s

d. Mass flow rate for the cold fluid

 m3  kg  kg
 cold = Vcold ρcold = 1.70 e − 5
m  995 3  = 0.0169
 s  m  s

e. The heat lost from the system

  
Q lost = Qhot − Qcold = 1.26 kW −1.55 kW = −0.290 kW

f. The temperature efficiency of the hot fluid

T3 − T1 68.6  C − 64.9  C
η hot = × 100% = × 100% = 15.1%
T1 − T4 64.9  C − 40.4  C

g. The temperature efficiency of the cold fluid

T4 − T6 40.4  C − 23.1 C
η cold = × 100% = × 100% = 70.6%
T1 − T4 64.9  C − 40.4  C

h. The mean temperature efficiency

η hot + η cold 15.1% + 70.6%
ηm = = = 42.9%
2 2
i. The overall efficiency for the system
Q cold 1.22kW
η= = = 160%
Q hot 0.763kW

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2. Hot fluid volume flow rate

( )

Vhot = ( Fhot ) 1.667 x10 −5 = 3.02
L 
(1.667 e − 5) = 5.03 e − 5
min 
m3
s


3. Cold fluid volume flow rate

Vcold = ( Fcold ) (1.667 x10 −5 ) = 1.02

 L  m3
(1 .667 e − 5 ) = 1 . 70 e − 5
 min  s

4. Midpoint hot water specific heat and density

kJ kg
T2 = 67 .7°C → c p ,hot = 4.19 , ρhot = 979 3
kg ⋅ C

m

5. Midpoint cold water specific heat and density

kJ kg
T5 = 31 .9  C → c p ,cold = 4.18 , ρcold = 995 3
kg ⋅ C m

6. The calculations in a through i use flowmeter and thermocouple data that is subject to
bias and precision error. The density of water decreases by about 0.7% between 0 and 38
ºC. If the standard deviation of temperature is ±0.1ºC, the temperature deviation is
around ±0.1% density standard deviation is 0.002% (at 95% confidence). The bias error
in the temperature reading can be estimated as ±1ºC, resulting in a bias density
uncertainty of ±0.02% (at 95% confidence).

1 1
 1 B ρ  2  2  1 
2 2

B =    =  × 0.002   = 0.001 %

 2 ρ    2  
1 1
 1 σ ρ  2  σ  2  2  1 2
2
σ =   +  T   =  × 0.02  + ( 0.1) 2  = 0.1%
 2 ρ   T    2  
P = 1.96σ = (1.96 )( 0.001 ) = 0.196 %

[ ] = [( 0.00001 ) ]
1 1
U = ( B) + ( P) + ( 0.00196 )
2 2 2 2 2 2
= 0.196 %

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Table 1 Experimental values
Hot water Cold water Hot outlet Hot midpoint
flow rate, Fhot flow rate, Fcold temp, T1 temp, T2
(ltr/min) (ltr/min) (deg C) (deg C)
3.02 1.02 64.9 67.7
3.02 2.02 60.3 63.4
3.02 3 54.5 57.8

Hot inlet Cold oultet Cold midpoint Cold inlet

temp, T3 temp, T4 temp, T5 temp, T6
(deg C) (deg C) (deg C) (deg C)
68.6 40.4 31.9 23.1
65.2 33.5 27.5 22.8
59.5 30.2 25.5 22.5

Table 2 Calculated values

Hot specific Hot density Cold specific Cold density Hot fluid volume
heat, cp,hot rho_hot heat, cp,cold rho_cold flow, V_dot_hot
(kJ/kg.K) (kg/m^3) (kJ/kg.K) (kg/m^3) (m^3/s)
4.19 979 4.18 995 0.0000503
4.19 981 4.18 996 0.0000503
4.18 984 4.18 997 0.0000503

Hot fluid mass Cold fluid volume Cold fluid mass Heat emitted Cold absorbed
flow, m_dot_hot flow, V_dot_cold flow, m_dot_cold Q_dot_hot Q_dot_cold
(kg/s) (m^3/s) (kg/s) (kW) (kW)
0.0493 0.0000170 0.0169 0.763 1.22
0.0494 0.0000337 0.0335 1.013 1.50
0.0495 0.0000500 0.0499 1.036 1.60

Heat loss Hot temp Cold temp Mean temp Overall

Q_dot_lost eff, eta_hot eff, eta_cold eff, eta_m efficiency, eta
(kW) (%) (%) (%) (%)
-0.46 15.10 70.61 42.86 160.19
-0.49 18.28 39.93 29.10 148.11
-0.57 20.58 31.69 26.13 154.87

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7.

1.8
Figure 5 Heat rate vs. cold water flow rate

1.6

1.4
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 Discussion of Results
The data obtained was consistent with the hypotheses with regards to temperature
variation at the heat exchanger outlets. In both experiments, the hot and cold water
streams approached an equilibrium temperature. When the cold water flow was
increased while keeping the hot water flow the same, both outlet temperatures decreased.
More heat was transferred from the hot stream to the cold stream at the higher cold water
flow rate, resulting in a greater hot stream temperature drop. The higher cold water flow
resulted in lower cold water outlet temperatures because the cold water was exposed to
the hot water in the heat exchanger for a shorter period of time.
At T1 (hot water inlet) the temperature dropped 9.1° C between experiment one and
three. This is possibly due to the larger cold water flow, which may have cooled the
tubular heat exchanger exterior. The hot water at the inlet may have been cooler as a
result of a larger temperature difference at contact with the heat exchanger, resulting in
heat transfer between the hot water stream and the exterior of the tubular heat exchanger.
Additionally, the tubes carrying the hot water towards the inlet may have been in contact
with the tubes carrying the cold water, resulting in heat loss from the hot stream before it
entered the heat exchanger.
There were a few noticeable sources of experimental error. The hot water
temperature at T1 (hot water inlet) was measured at 88.6° C in experiment one despite the
heater being set to 60° C. This is probably a consequence of not allowing the system to
warm up for long enough before beginning the experiment. Small air bubbles
(approximately 2mm diameter) trapped in the hot and cold water circuits may have
altered the volume flow measurements. Air pockets may have also caused temperature
variations and affected the speed of the water pump. Also, as the system warmed up, the
variables in the system probably became a little more consistent and efficient. Examples:
water density, temperature, flow rate, air bubbles, and pressure.
Despite the fact that the temperatures changed in accordance with the hypotheses, the
calculated efficiency for the heat exchanger was greater than 100%, indicating that the
cold water was absorbing more heat than the hot water was emitting. The efficiency of
the heat exchanger ranged from 148% to 160%. One possible explanation is that the cold
water experienced frictional heating as it entered the heat exchanger, resulting in an

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increased outlet temperature. However, it seems unlikely that frictional heating would
result in such a large increase in cold water temperature at the low flow rates of this
experiment. Thus, it seems more likely that these impossible efficiencies were the result
of faulty flow sensors or thermocouples, incorrect setup, or incorrectly primed flow. If
the cold water flow was measured as being higher than it actually was by a faulty flow
sensor, the calculated heat absorption of the cold water would also be higher than it
actually was, resulting in a higher calculated efficiency.

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 Lab Guide Questions
1. Did the heat exchanger remove more or less heat from the hot stream as the flow
rate of the cold water increased?
More heat was removed from the hot stream at the higher cold water flow rates
than at the lower cold water flow rates. The higher cold water flow results in a larger
average temperature difference in the heat exchanger, resulting in increased heat transfer
from the hot stream to the cold stream.

2. Did the system efficiency increase or decrease as the cold water flow rate increased?
The system efficiency decreased from experiment one to two, but increased from
experiment two to three, suggesting that the higher cold water flow does not have much
effect on the system efficiency. However, all overall efficiencies were over 100%,
making it difficult to make any definitive claims about the effect of flow on efficiency.
The data suggests that there is some other factor adding significant heat to the cold water
flow stream, thus increasing the apparent efficiency.

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 Conclusion
This lab went exactly as expected with regards to trend in temperature readings.
Add more cold water, and the outlet temperature of the hot water will go down. Cold
water temperature was increased by flowing next to hot water. The lab was very straight
forward, however, we have very little experience with running heat exchangers. It was a
great learning experience to get a hold on how much temperature change will take place
with varying opposing flows of water.

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 Works Cited

1. Kassegne, Sam. "Plate Heat Exchanger." Blackboard. SDSU Engineering. 21 Nov

2007 <https://blackboard.sdsu.edu>.

2. Armfield Engineering Education. 21 Nov. 2007 <http://www.armfield.co.uk/ >.

3. Beckwith, T., Marangoni, R., Lienhard, J. Mechanical Measurements 5th.

Addison-Wesley, New York, 89-91.

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