OBSERVED DATA

Shell: Nominal size 6

Schedule no = 40
Tubes: Number of tubes = 19
OD

= 0.5 inch

BWG

= 16

Length

= 96 inch

Pump: Centrifugal pump, 1.5kW; 240V; 50Hz; 2900rpm; Hmax=38m; Qmax=250l/h

Weight of the empty bucket W1 = 1.5 kg

Table 01: Observed data for Study of shell and tube heat exchanger

No
of
Obs

Steam
Pressure
(psig)

Flow
meter
reading
(L)

Water
Temperature
(C)
Inlet
(T1)

Outlet
(T2)

Weight of
condensat
e
+
bucket
(kg)

Manometer
Reading

Time
Water
(sec)

Condensate
(min)

Left
(inch)

Right
(inch)

10

24.5

32

2.45

11.1

33

36

10

24.5

31

2.7

8.79

32

36.7

10

24.5

30.5

6.91

30.6

37.5

10

24.5

29.5

3.2

5.54

27.5

38.8

10

27

34.5

3.1

10.09

32.6

36.4

10

27

33.5

3.65

8.6

31.5

37

10

27

32.5

3.75

30.1

37.5

10

27

31

3.9

5.72

27.4

38.8

2.5

CALCULATED DATA

Table 02: Calculated data for Mean, Saturation, Film and Wall temperature and Heat of
condensation and manometer reading in meter

No
Saturation
Mean
Film
Wall
Heat of
of Temperature, Temperature, Temperature, Temperature, Condensation
Obs
Ts (C)
Tm (C)
Tf (C)
Tw (C)
hfg (kJ/kg)

Manometer
Reading
Left
(m)

Right
(m)

104.44

28.25

75.86875

66.345

2244.6

0.8382

0.9144

104.44

27.75

75.68125

66.095

2244.6

0.8128

0.93218

104.44

27.5

75.5875

65.97

2244.6

0.77724

0.9525

104.44

27

75.4

65.72

2244.6

0.6985

0.98552

108.39

30.75

79.275

69.57

2234

0.82804 0.92456

108.39

30.25

79.0875

69.32

2234

0.8001

0.9398

108.39

29.75

78.9

69.07

2234

0.76454

0.9525

108.39

29

78.61875

68.695

2234

0.69596 0.98552

Table 03: Calculated data for properties of water at mean temperature and properties of
condensate at film temperature

Properties of water at mean temperature

No
of
Obs

Density
(kg/m3)

Viscosity
(kg/m.s)

Cp
(kJ/kg.C)

Thermal
conductivity
(W/m.C)

Properties of condensate at film

temperature

Density
(kg/m3)

Viscosity
(kg/m.s)

Thermal
conductivity
(W/m.C)

995.96

0.00083865 4.18056775

0.6165596

974.27875 0.00037466

0.6684263

996.12

0.00084655 4.18063425

0.6157496

974.39125 0.00037559

0.6682913

996.2

0.0008505

4.1806675

0.6153446

974.4475

0.00037606

0.6682238

996.36

0.0008584

4.180734

0.6145346

974.56

0.000377

0.6680888

995.16

0.00079915 4.18023525

0.6206096

972.235

0.00035763

0.6708788

995.32

0.00080705 4.18030175

0.6197996

972.3475

0.00035856

0.6707438

995.48

0.00081495 4.18036825

0.6189896

972.46

0.0003595

0.6706088

995.72

0.0008268

0.6177746

972.62875 0.00036091

0.6704063

4.180468

Table 04: Calculated data for water and condensate flow rate, Heat rate of water and steam
and mean heat rate

Water
No of
Flow
Obs Rate, mw
(kg/s)

Condens
ate Flow
rate, mc
(kg/s)

Heat
absorbed
by water
Qw (kW)

Heat
released by
steam, Qc
(kW)

Heat loss
(kW)

Percent
heat loss

Mean Heat
Flow, Qm
(kW)

0.89726

0.00791

28.1329612

17.76975

-10.363

-58.31

22.9513556

1.13324

0.01

30.7948658

22.446

-8.3488

-37.19

26.6204329

1.44167

0.0125

36.1630764

28.0575

-8.1055

-28.88

32.1102882

1.79848

0.01416

37.5949109

31.7985

-5.7964

-18.22

34.6967055

0.98628

0.0133

30.9217263 29.7866667

-1.1350

-3.81

30.3541965

1.15734

0.01791

31.4474379 40.0258333

8.57839

21.43

35.7366356

1.42211

0.01875

32.6972877

41.8875

9.19021

21.94

37.2923939

1.7407

0.02

29.1089203

44.68

15.57

34.85

36.8944601

Table 05: Calculated data for tube and shell side heat transfer co-efficient

No
of
Obs

Tube side
Reynolds'
No

Tube Side
prandtl no.

Viscosity
of water at
wall
temperature
(kg/m.s)

Tube side
Nusselt No

67.57398

jH value

Tube side
heat
transfer
coefficient,
hi
(W/m2.C)

Shell side
heat transfer
coefficient,
ho
(W/m2.C)

7623.25572 5.68644644 0.00042666

34.4410319 4433.21835

4730.50156

9538.33328 5.74765444 0.00042821 81.1978593 41.2042258 5320.02015

4719.37987

12078.0409 5.77831951 0.00042899 98.2895119 49.7692343 6435.61613

4713.85036

14928.6017 5.83977219 0.00043054 116.949833 58.9629319 7647.34185

4702.85325

8793.78339 5.38282843 0.00040667 74.3788083 38.6104066 4911.70488

4765.7861

10218.0062 5.44323121 0.00040822

43.5368188 5556.47796

4754.58813

12433.8567 5.50379377 0.00040977 99.0236978 50.9387695 6522.09397

4743.47295

15001.7891 5.59493858 0.00041209 115.845814

84.252684

59.194071

7615.08844

4726.953

Table 06: Calculated data for experimental and theoretical overall heat transfer coefficient

Overall
Experimental
heat transfer
coefficient,
UoE
(W/m2.C)

Overall
Theoretical
heat transfer
coefficient,
UoT
(W/m2.C)

No of Obs

Mass velocity
of water
(kg/m2.s)

LMTD (C)

Outside
surface area
of 19 tubes
(m2)

680.277018

76.1284364

1.84847321

163.0978635

1937.165799

859.190895

76.6440681

1.84847321

187.8985402

2146.361712

1093.03828

76.9009928

1.84847321

225.891088

2368.989501

1363.55732

77.41309

1.84847321

242.4714874

2568.412839

747.771014

77.5795876

1.84847321

211.6694175

2062.035309

877.467745

78.0949212

1.84847321

247.5584263

2204.945136

1078.2051

78.6079342

1.84847321

256.6496755

2392.27619

1319.79988

79.3732024

1.84847321

251.4630026

2570.629003

Table 07: Calculated data for tube side experimental and theoretical pressure drop

No
of
Obs

Experiment
al Pressure
Drop from
manometer
reading,
(Pa)

Friction
Specific
factor
gravity,
(sq ft/sq
s
inch)

10161.8141

0.0003

15920.1754 0.00027 0.99612

23372.1724 0.00025

Pressure
drop due to
velocity
head (Pa)

Total
Theoretical
Pressure
drop PT
(Pa)

1.09923283

2362.721233 937.945183

3300.66642

1.100118

3388.780082 1495.46379

4884.24387

0.9962

1.10055656

5075.783231 2419.70643

7495.48967

38276.1663 0.00023 0.99636

1.10142577

7260.296222 3763.82565

11024.1219

12871.6312 0.00028 0.99516

1.09919479

2666.729295

1136.0307

3802.75999

18629.9925 0.00026 0.99532

1.10012354

3406.298481 1563.52805

4969.82653

25065.808

0.00024 0.99548

1.10104053

4742.740664 2359.59079

7102.33145

38614.8935 0.00023 0.99572

1.10239447

6800.188707 3532.93806

10333.1268

0.99596

t
(/w)^0.14

Pressure
drop through
tubes Pt
(Pa)

GRAPHS

1) jH factor vs Reynolds No

a) for 2.5 psig steam pressure:

jH Factor vs Reynolds' No for 2.5 psig Steam Pressure

jH Factor

100

y = 0.8001x +log0.00395

10
1000

10000

100000

Reynolds' No

Figure 02: jH Factor vs Reynolds' No for 2.5 psig Steam Pressure

10

b) for 5 psig steam pressure

jH Factor vs Reynolds' No for 5 psig Steam Pressure

jH Factor

100

y = 0.8001x +log0.00395

10
1000

10000

100000

Reynolds' No

Figure 03: jH Factor vs Reynolds' No for 5 psig Steam Pressure

11

2) Pressure drop vs velocity of water\

a) For 2.5 psig steam pressure

Pressure Drop vs Velocity of Water for 2.5 psig Steam

Pressure
40000

35000

Pressure Drop (Pa)

30000

25000

20000

Experimental
Theoretical
15000

10000

5000

0
0.6

0.7

0.8

0.9

1.1

1.2

1.3

1.4

Velocity of Water (m/sec)

Figure 04: Pressure Drop vs Velocity of Water for 2.5 psig Steam Pressure

12

b) For 5 psig steam pressure:

Pressure Drop vs Velocity of Water for 5 psig Steam

Pressure
40000

35000

Pressure Drop (Pa)

30000

25000

20000

Experimental
Theoretical
15000

10000

5000

0
0.7

0.8

0.9

1.1

1.2

1.3

1.4

Velocity of Water (m/sec)

Figure 05: Pressure Drop vs Velocity of Water for 5 psig Steam Pressure

13

SAMPLE CALCULATION
For observation no. 2 (2.5 psig steam pressure):
Water inlet temperature, T1

= 24.5oC

Water outlet temperature, T2

= 31oC

Water mean temperature, Tm

T1 T2
=
2

24.5 31
2

= 27.75oC

Properties of water at mean temperature (27.75oC),

Density,

= 996.12 kg/m3

Viscosity,

= 0.00084655 kg/m.sec

Thermal conductivity, k = 0.6157496 W/m. oC

Specific Heat, Cp

= 4.18063425 kJ/kg. C

[From J. P. Holman, Heat Transfer, McGraw - Hill, 10th Ed, 1997, Page-605, Table A-5]
Saturation temperature at 2.5 psig steam pressure, Ts = 104.44oC
Heat of Condensation at 2.5 psig steam pressure, hfg

= 2244.6 kJ/kg

[From J M Smith, H C Van Ness, M M Abbott, Chemical Engineering Thermodynamics,

McGraw - Hill, 7th Ed, 2001, Page-715, Table F1]
Weight of bucket and condensate = 2.7 kg
Weight of empty bucket

= 1.5 kg

Weight of condensate

= (2.7-1.5) kg
= 1.2 kg

Time of condensate taken = 2 minutes

Mass flow rate of condensate, mc =

1.2 kg
2 60 sec

= 0.01 kg/sec
Heat released by condensation, Qc = mchfg
= (0.012244.6) kW
= 22.446 kW

14

Volume of water taken = 10L

Time of water taken = 8.79 sec
Mass flow rate of water, mw

10 10 3 m 3 996.12kg / m 3
=
8.79 sec
= 1.133242321 kg/sec
Heat absorbed by water, Qw

= mwCp(T2-T1)
= 1.1332423214.18063425(31-24.5)
= 30.79486579 kW
= (Qc Qw)

Heat loss

= (22.446 - 30.79486579) kW
= -8.3489 kW
Percent heat loss

(QC QW )
100%
QC

= -37.195 %
Average heat transfer, Qavg

Q w Qc
2

30.79486579 22.446
2

= 26.6204 kW
Logarithmic Mean Temperature Difference,
LMTD

(Ts T1 ) (Ts T2 )
T T1

ln s
Ts T2

(104.44 24.5) (104.44 31)

104.44 24.5
ln

104.44 31

= 76.6441 C

15

For nominal size 6 & schedule 40 steel tube,

Inside diameter (ID) of the tube,

Di = 0.37 inch = 0.009398 m

Outside diameter (OD) of tube, Do = 0.5 inch

[From Donald Q. Kern, Process Heat Transfer, McGraw - Hill, International Ed, 1997,
Page-843, Table 10]
= n Do L

Outsied area of 19 tube

= 190.596 inch2
= 2865.14 inch2
= 1.84847 m2
Experimental overall heat transfer co-efficient,
UOE

Q avg
A 0 LMTD
26.6204 1000
1.84847 76.6441

= 187.8985 W/m2. C
Flow area of tube, Ai

19 0.1076
inch2
1

= 2.0444 inch2
= 0.001318965 m2

Velocity of water

=
=

1.133242321
0.001318965 996.12

= 0.86254 m/sec
Mass velocity of water,

=
=

1.133242321
= 859.191 kg/m2sec
0.001318965

16

Reynolds number, Re

Di v w

0.009398 0.86254 996.12

0.00084655

= 9538.333
Wall temperature

Tw

[Ts 0.5 (T1 T2 )]

2
= 66.095 oC

Prandtl Number, Pr

= 5.74765

Viscosity of water at wall temperature = 0.000428211 kg/m.sec

[From J. P. Holman, Heat Transfer, McGraw - Hill, 10th Ed, 1997, Page-605, Table A-5]
Using Seider-Tate equation,
Nu=0.027 Re0.8 Pr1/3 (/w) 0.14
= 0.027 (9538.333)0.8 (5.74765)1/3(0.00084655/0.000428211)0.14
= 81.1978
jH factor calculation,

-1/3

jH = Nu .Pr

.
w

0.14

= 41.2042

Tube side heat transfer coefficient

hi = Nu

k
Di

= 81.1978

0.6157496
0.009398

= 5320.0201 W/m2. C

17

= Ts 0.75 (Ts-Tw)

Film temperature, Tf

= 75.68125 oC
Properties of condensate at film temperature (75.68125oC),
Density, f

= 60.859 kg/m3

Viscosity, f

= 0.907023 kg/m.sec

Thermal conductivity, kf = 0.386105 W/m.C

[From J. P. Holman, Heat Transfer, McGraw - Hill, 10th Ed, 1997, Page-605, Table A-5]
Density of steam, v

Saturation temperature, Tg =Ts = 104.44 C

Using Nusselt equation, steam side heat transfer co-efficient,

ho

f ( f v )gh fg k f 3

= 0.725
f nd(Tg Tw )
f 2 gh fg k f 3

= 0.725
f D o (Tg Tw )

0.25

0.25

= 4719.3798 W/m2. C
Theoretical overall heat transfer co-efficient,
UOT

1
D
o
=
h 0 Di h i

-1

= 2146.362 W/m2. C
Pressure Drop Calculation:
For Reynolds no = 9538.333
The value of friction factor, f = 0.00027 sq ft/sq inch
[From Donald Q. Kern, Process Heat Transfer, McGraw - Hill, International Ed, 1997,
Page-836, Figure 26]
Mass velocity of water Gt = 633513.753 lb/hr.ft2
Length of the tube, L = 8 ft
No of tube passes, n = 1
18

Inner diameter of tube, D = 0.03083333 ft

Specific gravity, s = 0.99612
Pressure drop through tube,
Pt =

f Gt 2 L n
5.22 1010 D s ( / w ) 0.14

= 0.491500997 psi
= 3388.780082 Pa
Velocity of water, v = 2.82985 ft/s
Acceleration of gravity, g = 32.174 ft/s2
Velocity head,

v2
= 0.1244489 ft
2g'

Pressure drop due to velocity head, Pr =

4 n v 2 62.5

s
2 g ' 144

= 0.21689868 psi
= 1495.464 Pa
Total pressure drop, PT = Pt+ Pr
= 4884.24387 Pa
Difference in manometer height, h = (0.93218- 0.8128) m Hg
= 0.11848 m Hg
Density of mercury, Hg = 13594 kg/m3
Experimental pressure drop = hHgg
= 0.11848 13594 9.81
= 15920.175 Pa

19

RESULTS AND DISCUSSIONS

Range of Overall Heat transfer co-efficient:

Experimental Values -------Theoretical Values

--------

163.1 to 256.54 W/m2. C

1937.2 to 2570.6 W/m2. C.

Range of Pressure drop:

Experimental Values --------

10161.8 to 38614.9 Pa

Theoretical Values --------

3300.7 to 11024.12 Pa

Some of the heat loss found in this experiment were a negative value. But that was not
expected. The condensate was collected through a steam trap, in which the flow was not
continuous. As a result condensate flow rate was not steady for this experiment, hence
negative heat loss encountered in the experiment. The steam pressure was considered
constant during the experiment but it was not constant. Heat lost during the experiment due to
convection and conduction was not also considered.
Two types of graphs were drawn in the experiment. From the 1st type of graph, jH factor vs
reynolds no the slope was found 0.8001 both for 2.5 and 5 psig steam pressure, which proves
the validity of Sieder-Tate equation.
From the 2nd type of graph, pressure drop vs velocity of water the experimental pressure drop
was found somewhat greater than the theoretical pressure drop both for 2.5 and 5 psig steam
pressure. The theoretical values found in this experiment were not absolutely theoretical.
These values are found based on some parameters that are determined experimentally in one
way or another. Hence, they cannot be said to be purely theoretical. However, these
theoretical values can be of great importance when reasonable approximation and comparison
are required in real life consequence. One of the important things in shell and tube exchanger
operation is the pressure limitation that must be abided both in shell and tube sides. Beyond
this pressure limits the system can become unstable and materials of construction is affected
mainly due to corrosion and erosion.
Excess fouling might encounter in tube side which decrease the overall heat transfer coefficient.

20

After two consecutive reading we have to pause our experiment meanwhile heat exchanger
lost its current status & become cool .Thereby temperature exchange not happen linearly
which is great obstacle to perform this experiment.

21