1.

Introduction
Heat exchangers are popular used in industrial and engineering applications. The design
procedure of heat exchangers is quite complicated, as it needs exact analysis of heat transfer rate,
efficiency and pressure drop apart from issues such as long- term performance and the economic
aspect of the equipment. Whenever inserts technologies are used for the heat transfer
enhancement, along with the improvement in the heat transfer rate, the pressure drop also
increases, which induces the higher pumping cost. Therefore any augmentation device or
methods utilized into the heat exchanger should be optimized between the benefits of heat
transfer coefficient and the higher pumping cost owing to the increased frictional losses. In
general, heat transfer augmentation methods are classified into three broad categories:
1.1

Heat transfer enhancement techniques

High thermal loads due to miniaturization in a wide variety of applications like microelectronics,
transportation, lighting, utilization of solar energy for power generation etc., offers technological
challenges in designing efficient thermal management systems. Hence in recent years, heat
transfer enhancement technology has been widely applied to heat exchanger applications. The
goal of enhanced heat transfer is to encourage or accommodate high heat fluxes. This results in
reduction of the heat exchanger size which in turn leads to less capital cost. Another advantage is
the reduction of the temperature driving force, which reduces the entropy generation and
increases the second law efficiency. In addition, heat transfer enhancement enables heat
exchangers to operate at smaller velocity to achieve the same or higher heat transfer coefficient.
This means that a reduction of pressure drop may be achieved. All these advantages have made
heat transfer enhancement technologies attractive in heat exchanger applications.

Heat transfer enhancement techniques can be broadly classified into three categories as
(i)

Passive techniques

(ii)

Active techniques

(iii)

Compound techniques

Passive techniques require no direct application of power whereas active techniques require
external power. A compound technique is a hybrid method in which both active and passive
methods are used in combination. The compound method involves complex design and hence
has limited applications [1-3].
1.1.1

Passive techniques

Examples for passive techniques are treated and structured surfaces, rough surfaces, extended
surfaces, displaced enhancement devices, swirl flow devices, additives for liquids and gases, etc.
(i) Treated and structured surfaces
Treated and structured surfaces increase the heat transfer coefficients by altering the surface
finish or coating. They are suitable for two-phase flow heat transfer like boiling and
condensation and are not discussed here.
(ii) Rough surfaces
Rough surfaces can be of many types like coil insert, knurling, high transverse ribs, threads,
roughness screen, low transverse ribs, spirally fluted tubes, transverse grooves, sand grains, etc.
Artificially roughened surfaces promote turbulence rather than increasing the heat transfer
surface area. Rough surfaces find application mainly in single-phase flow heat transfer.
(iii) Extended surfaces
Extended surfaces are widely used in the compact heat exchangers. Integral inner-fin tubing
specially shaped and interrupted extended surfaces are of particular interest.

(iv) Displaced enhancement devices

Tubes having inserts like metallic mesh, static mixer elements, rings, disks or balls are known as
displaced enhancement devices. The heated surface remains intact and the insert alters fluid flow
near the surface.
(v) Swirl flow devices
Twisted tapes, helical vanes, spiral corrugations, etc. are known as swirl flow devices in view of
the fact that these devices augment the heat transfer by inducing a swirl in the flow.
(vi) Surface tension devices
Surface tension devices are tubes with wicking or grooved surfaces directing the flow of liquid
during boiling or condensation.
(vii) Additives
Additives used for liquids are solid particles and gas bubbles in single-phase flows while in
boiling heat transfer, liquid additives are used. Liquid droplets or solid particles are used as
additives for heat transfer processes involving gases.
1.1.2 Active techniques
This method involves some external power input for the enhancement of heat transfer and has
not shown much potential owing to the complexity in design. Furthermore, external power is not
easy to provide in several applications. Some examples of active methods are induced pulsation/
vibrations in fluid/surfaces by cams and reciprocating plungers, the use of magnetic field to
disturb the seeded particles in a flowing stream, etc.
Amongst a host of heat transfer enhancement techniques described above, the swirl flow tube
inserts have been reported widely in the literature. The main advantage of these types with

respect to other enhancement techniques is that they allow an easy installation in an existing heat
exchanger and low cost.
An extensive literature review of all types of heat transfer augmentation technique with external
inserts has been discussed by Dewan et al. [4] up to 2004

2. Literature Review
Twisted tapes are the metallic strips twisted with some suitable techniques at desired shape and
dimension, inserted in the flow. The twisted tape inserts are popular and widely used in heat
exchangers for heat transfer augmentation besides twisted tape inserts promote heat transfer rates
with less friction factor penalty on pumping power
Insertion of twisted tapes in a tube provides a simple passive technique for enhancing the
convective heat transfer by introducing swirl into the bulk flow and disrupting the boundary
layer at the tube surface due to repeated changes in the surface geometry. That is to say such
tapes induce turbulence and superimposed vortex motion (swirl flow) which induces a thinner
boundary layer and consequently results in a better heat transfer coefficient and higher Nusselt
number due to the changes in the twisted tape geometry. However, the pressure drop inside the
tube will be increased by introducing the twisted-tape to insert. Hence a lot of researches have
been carried out experimentally and numerically to investigate the optimal design and achieve
the best thermal performance with less frication loss. The enhancement of heat transfer using
twisted tapes depends on the Pitch and Twist ratio.
Large number of experimental work are carried out by researchers to investigate the
thermohydraulic performance of various twisted tapes including the traditional simple twisted
tapes, regularly spaced twisted tapes, varying length twisted tapes, tapes with different cut
shapes, tapes with baffles and tapes with different surface modifications [5]. The other several
passive techniques to enhance the heat transfer in a flow, such as ribs, conical nozzle, are
generally more efficient in the turbulent flow than in the laminar flow.
Heat transfer enhancement was investigated by chen et al. [6] in a coaxial-pipe heat exchanger
using dimples as the heat transfer modification on the inner tube. Heat transfer enhancement

ranged from 25% to 137% at constant Reynolds number, and from 15% to 84% at constant
pumping power. At a constant Reynolds number, the relative J factor (ratio of heat transfer
coefficient to friction factor, relative to smooth tube values), had values from 0.93 to 1.16
Vicente et al. [7] presented the experimental results carried out in dimpled tubes for laminar and
transition flows. Their experimental results of isothermal pressure drop for laminar flow showed
dimpled tube friction factors between 10% and 30% higher than the smooth tube ones. Heat
transfer augmentation depends on Rayleigh number; at high Rayleigh numbers, Nu
augmentations up to 30% were obtained whereas at low Rayleigh numbers, Nusselt number was
even lower.
Friction and compound heat transfer behaviors in a dimpled tube fitted with a twisted tape swirl
generator are investigated experimentally by Thianpong et al. [8] using air as working fluid. The
experimental results reveal that both heat transfer coefficient and friction factor in the dimpled
tube fitted with the twisted tape, are higher than those in the dimple tube acting alone and plain
tube. It is also found that the heat transfer coefficient and friction factor in the combined devices
increase as the pitch ratio (PR) and twist ratio (y/w) decrease. In addition, an empirical
correlation based on the experimental results of the present study is sufficiently accurate for
prediction the heat transfer (Nu) and friction factor ( f ) behaviors.
Wang et al . [9] investigated the heat transfer and hydrodynamics analysis of a new enhanced
heat transfer tube with ellipsoidal dimples. Experimental tests were carried out with heating
water on the shell side with a constant flow rate, and cold air in the tube side with flow rates
range from 1 to 55 m3/h. The computed results indicated that the Nusselt number for ellipsoidal
dimpled tube and spherical dimpled tube are 38.6175.1% and 34.1158% higher than that for

the smooth tube respectively. The friction factors of dimpled tube increase by 26.975% and
32.992% for ellipsoidal and spherical dimples compared with the smooth tube respectively.
The helical inserts are new addition to the family of inserts for enhancement of heat
transfer. For the helical taps, the swirl moves in one direction along the helical and induce swirl
in the flow, which increase the retention time of the flow and consequently provide better heat
transfer performance over twisted tape insets. The high heat transfer with helical inserts is also
accompanied by a higher pressure drop across the flow, but at low Reynolds number, helical
tapes are used in solar water heating applications to drive heat transfer benefit. However inserts
of different configuration are being used to meet the needs of higher heat dissipation rates. Wire
coil inserts are currently used in the applications such as oil cooling devices, pre heaters or fire
boilers. They show several advantages in relation to other enhancement techniques [5, 10-12]

Simple manufacturing process with low cost

Easy installation and removal
Preservation of original plain tube mechanical strength
Possibility of installation in an existing smooth tubeheat exchanger
Fouling mitigation (in refineries, chemical industries and marine application)

From the literature review it is understood that a large number of experimental work are
carried out by researchers to investigate the thermohydraulic performance of various twisted
tapes including the traditional simple twisted tapes, regularly spaced twisted tapes, varying
length twisted tapes, tapes with different cut shapes, tapes with baffles and tapes with different
surface modifications. Only few works has been reported on the thermal and pressure drop
characteristics of wire coil inserts. Hence the purpose of the present work is to experimentally
investigate the effect of wire coil inserts on the heat transfer and pressure drop performance of
water under laminar flow with constant heat flux.
7

3. Objectives and Methodology of the present work

3.1 Objectives

The purpose of the present work is to experimentally investigate the effect of wire coil
insert on the heat transfer and pressure drop performance of water under laminar flow with
constant heat flux. The following are the objectives of the present work

To measure the fluid inlet and outlet temperatures, wall temperatures

To measure the mass flow rate of water
To measure the heat input given to the tube surface and Nusselt number
To measure the pressure drop and calculate the friction factor
To find the enhancement and performance ratio of wire coil inserts

3.2 Methodology
The program of activities involved in the present investigation is shown in Fig. 3.1

Enhancement of heat transfer characteristics of water in circular tube fitted with

wire coil insert under laminar flow

Without wire coil inserts

With wire coil inserts

Heat transfer studies

Pressure drop studies

Enhancement ratio

Conclusions

Fig. 3.1Methodology

10

4. Convective experimental setup

The experimental setup for measuring the convective heat transfer and pressure drop
characteristics is shown schematically in Fig. 4.1. The test loop consists of a pump, calming
section, heated test section, cooling section, a collecting station and a reservoir. The pump used
in this work was of peristaltic type (RH-P120l, Ravel Hiteks Pvt. Ltd.) in which the flow rate
was controlled by the rotational speed. The pump could deliver a maximum flow rate of 2.55
liters per minute. Fluids were driven by the pump from the reservoir to flow through the test
loop. A four liter capacity stainless steel vessel equipped by drain valve is used as fluid reservoir.
In order to control the fluid flow rate, a reflux line with a valve was used. Calming section of
straight copper tube 800 mm long, 4.85 mm inner diameter, and 6.3 mm outer diameter is used to
eliminate the entrance effect and to ensure fully developed flow in the test section. A dimpled
straight copper tube with 1200 mm length, 4.85 mm inner diameter, and 6.3 mm outer diameter
was used as the test section. The test section is first wound with sun mica to isolate it electrically.
Then, ceramic beads coated electrical SWG Nichrome heating wire giving a maximum power of
300 W is wounded over it. Over the electrical winding, thick insulation consisting of layers of
ceramic fiber, asbestos rope, glass wool and another layer of asbestos rope at the outer surface is
provided to prevent the radial heat loss. The test section is isolated thermally from its upstream
and downstream sections by plastic bushings to minimize the heat loss resulting from axial heat
conduction. The terminals of the Nichrome wire are attached to the Auto-transformer, by which
the heat flux can be varied by varying the voltage. Six calibrated RTD Pt100 type temperature
sensors with 0.1C accuracy are placed in thermowells mounted on the test section at axial
positions in mm of 110 (T3), 210 (T4), 410 (T5), 610 (T6), 760 (T7) and 870 (T8) from the inlet of
11

the test section to measure the wall temperature distribution. The inlet and outlet temperatures, T1
and T2 respectively, were measured by two RTD Pt100 type temperature sensors immersed in the
mixing chambers provided at inlet and exit. A differential pressure transducer (SGM srl, Italy)
able to read up to 1 cm of water is mounted across the test section to measure the pressure drop.
The fluid after passing through the heater section flows through a riser section and then through
the cooling unit which is an air cooled heat exchanger and is collected in the reservoir. A threeway valve is provided in the flow pipe connecting the cooler section and reservoir for flow rate
measurements and cleaning the system between successive experimental runs. The flow rates
were measured by collecting the fluid in the collecting station for a period of time with the help
of a precise measuring jar and stop watch.

Fig. 4.1 Schematic of the experimental setup

12

The photograph and the schematic of the test are shown in Fig. 4.2.

Control panel
Temperature
scanner

Test section
Control valves

Cooling section

Reservoir
Collecting station
4.2 Photograph the experimental setup
4.1 Details of wire coil inserts
Fig. 4.3 shows the wire coil inserts fabricated using 0.5 mm stainless steel wire having a coil
diameter of 4.5 mm. The coil pitch ratio which is defined as the ratio of pitch of the coil to
diameter of tube is selected as 2 and 3, and they are designated as WC1 and WC2 respectively.
The photograph is shown in Fig. 4.4.
1

13

Fig. 4.3 Wire coil inserts of pitch ratio 3 (WC2) and 2 (WC1)
Fig. 4.4 Photograph of Wire coil inserts of pitch ratio 3 (WC2) and 2 (WC1)

5. Data reduction
5.1 Heat transfer calculation
The heat transfer performance is defined in terms of the Nusselt number (Nu) and heat transfer
coefficient (h) as given below
h

q ''
(Tw T f )

Nu

and

hd
k

(5.1)

14

Here, Tw is the average temperature of the wall and Tf is the average bulk temperature of fluid,

q ''
is the actual heat flux, d is the tube diameter and k is the fluid thermal conductivity.
The heat losses from the test section are taken into account while calculating the actual heat flux
which was taken to be the average of the following two evaluations. The total heat generated by

Qt VI
the electrical heater is calculated as

Qloss
. The heat loss from the insulation (

) is

estimated as 2.5% of the total heat from the measurements of wall temperature (Tw) and ambient
temperature (Tamb). Therefore, the heat input from the electrical heater is

Q1 Qt Qloss
(5.2)
Heat input was also calculated from the sensible heat gained by the fluid as
Q2 m c p (Tout Tin )

(5.3)
The heat balance between the heat input from the heater (Q1) and heat input to the fluid (Q2)
was found to be within 3.2% for all runs. The actual heat flux is then evaluated as

q"

0.5(Q1 Q2 )
dL

(5.4)

5.2 Pressure drop calculation

15

The pressure drop (P) across the test section was measured using a differential pressure
transducer under isothermal flow conditions. It is used to calculate the friction factor by the
following equation
P

d
v L

(5.5)

Nu wc

f wc

Performance or Enhancement ratio,

Nu plain

f plain

1
3

(5.6)

5.3 Uncertainty analysis

All the quantities that are measured to estimate the Nusselt number and the friction factor are
subjected to uncertainties due to the errors in the measurement. Hence, uncertainty analysis is
carried out using Coleman and Steele method [13] and ANSI/ASME standards [14] considering
the measurement errors whereas the possible errors in the fluid properties are not included. For
this purpose, quantities like the tube diameter (d), Length of the test section (L), mass flow rate
(m), pressure drop (P), voltage (V), current (I), wall temperature (Tw) and fluid average
temperature (Tf) are measured and the probable errors in each of them are calculated to estimate
the uncertainties associated with experimental data of Reynolds number, friction factor and
Nusselt number using the following equations

Re m

Re
m

2
d

0.5

(5.7)

16

f (p )

f
p

Nu (V )

Nu V

d
3

2
Re
2

Re

Tw

Tw

0.5

2
T f

T
f

(5.8)
0.5

(5.9)

The calculations indicated that the uncertainties involved in the estimations are within 2.5% for
friction factor and 3 % for Nusselt number (excluding the heat losses from the insulation and
the difference in heat balance). The uncertainty in Reynolds number estimations is 0.65%. The
details of the uncertainty analysis are provided below

Table 5.1 Probable error involved in the measurements

Sl.No.
1
2
3
4
5
6
7
8
9

Measured quantity (x)

Probable error (x)

Voltage (v)
Current (I)
Pressure drop (h)
Pipe diameter (d)
Pipe length (L)
Mass flow rate (m)
Inlet temperature (Tin)
Outlet temperature (Tout)
Wall temperature (Tw)

V = 0.6 V
I = 0.036 A
(h) = 0.0033m
d = 0.00002 m
L= 0.001 m
m = 7.01x10-5 kg/s
Tin= 0.1 C
Tout = 0.1 C
Tw = 0.1 C

6. Results and discussion

The observed experimental values for the Nusselt number and friction factor are tabulated in
Table 6.1 6.6. The discussion on the results are given in the following sections
17

6.1 Validation of the experimental system

Initially experiments were conducted with distilled water in plain tube which forms the basis for
comparison of results as well as validation of the experimental apparatus. Fig. 6.1 shows that the
comparison of the experimental data with the Shah equation [15] given by Eq. 6.1 for laminar
flows under the constant heat flux boundary condition are in good agreement.

Nu 1.953 Re Pr
x

Re Pr

for

Nu 4.364 0.0722 Re Pr
x

d
33.33
x

Re Pr

for

(6.1)

d
33.33
x

Fig. 6.2 shows the variation of friction factor with Reynolds number under isothermal condition
which indicates it follows the Hagen-Poiseuille equation for laminar
f

64
Re

(6.2)

Fig. 6.1 Comparison between Shah equation and experimental data for Nusselt number of
distilled water under laminar flow

Fig. 6.2 Comparison between Poiseuille equation and experimental friction factor data of
distilled water under laminar flow

18

Table 6.1 Experimental heat transfer test data for plain tube
Run No.
1
2
3
4
5
6

M
kg/s
0.00281
4
0.00324
8
0.00389
8
0.00476
4
0.00541
4
0.00606
4

V
v

I
A

924

48

1.37

1067

50

1.35

1280

49

1.32

1564

50

1.35

1778

50

1.35

1991

50

1.34

Ti
C
35.
1
35.
1
35.
9
36.
2
36.
4
37.
1

2275

50

1.36

37

Re

7
0.00693

To
C
40.
3
39.
9
39.
6
39.
3
39.
2
39.
6
39.
3

T1
C
37.
4
37.
2
37.
1
37.
1
37
37.
2
37

T2
C
39.
3
38.
6
38.
5
38.
5
38.
5
39.
5
39.
3

T3
C
39.
9
39.
9
39.
9
39.
9
39.
9
40.
2
40

T4
C
40.
4
40.
3
40.
3
40.
3
40.
3
40.
9
40.
4

T5
C

T6
C

Tw
C

41
41.
1
41.
1
41.
1
41.
1
41.
7
41.
1

41.9

40 64.12 61.03 62.58

12.03

41.6

39.8 65.81 65.02 65.42

12.58

41.6

39.8 63.06 60.14

61.6

13.29

41.7

39.8 65.81 61.59

63.7

13.74

41.7

39.8 65.81 63.21 64.51

14.27

42

40.3 65.33 63.21 64.27

14.58

41.9

40

Q1
W

Q2
W

Q
W

Nu

66.3 66.46 66.38

15.87

Table 6.2 Experimental heat transfer test data for tube with WC1
Run No.
1

M
kg/s
0.00221
6

Re

V
v

728

61

0.00288
0.00332

945
109

61
61

2
3

I
A
1.6
5
1.6
6
1.6

Ti
C
33.
3
33.
9
35.

To
C
43.
6

T1
C

42
42.

35.8
36.3

36

T2
C
39.
6
38.
1
39.
19

T3
C

T4
C

40.5

42.9

39
40.8

42.1
43.1

T5
C
44.
2
43.
9
44.

T6
C

Tw
C

Q1
W

Q2
W

Q
W

Nu

44.8

41.3

98.13

95.18

96.66

15

44.2
45.3

40.5
41.6

98.73
98.13

97.27
95.64

98
96.89

17
17.49

4
5

4
0.00398
9
0.00487
5

6
7
8

0.00554
0.00620
5
0.00709
1

1
131
0
160
1
181
9
203
7
232
8

62

5
1.6
5
1.6
6
1.6
9

63

1.7

63

1.7

61
61

7
36.
7
37.
5
37.
6
37.
8
38.
1

6
42.
4
42.
2
41.
9
41.
8
41.
6

36.1
36.1
35.8
35.9
35.8

8
39.
7
39.
7
39.
5
39.
5
39.
4

40.6

42.9

40.6

42.9

40.5

42.7

40.5

42.7

40.4

42.6

5
44.
3
44.
3
44.
1
44.
2
44.
1

45.1

41.5

98.13

94.81

96.47

21.88

45.1

41.5

95.55

97.14

26.04

44.9

41.3

99.33

100.75

28.75

44.9

41.3

103.49

103.96

30.66

44.6

41.2

98.73
102.1
6
104.4
2
104.4
2

103.49

103.96

34.06

Table 6.3 Experimental heat transfer test data for tube with WC2
Run No.
1
2
3
4
5
6

m
kg/s
0.00216
6
0.00281
4
0.00324
8
0.00389
8
0.00476
4
0.00541
4

Re

V
v

711

50

924

48

1067

50

1280

49

1564

50

1778

50

I
A
1.3
5
1.3
7
1.3
5
1.3
2
1.3
5
1.3
5

Ti
C
35.
1
35.
9
36.
3
36.
9
37.
2
38

To
C
42.
2
41.
3
40.
9
40.
7
40.
5
40.
8

T1
C

T2
C

T3
C

T4
C

T5
C

T6
C

Tw
C

35.1

37.7

38.3

41.7

43.1

44.2

40

34.9

37.5

38.1

41.5

42.9

44.1

39.8

34.8

37.5

38.1

41.5

42.9

44

39.8

34.7

37.4

38.1

41.5

42.9

43.9

39.8

34.7

37.4

38.1

41.5

42.9

43.9

39.8

35.1

37.8

38.7

41.7

43.5

44.8

40.3

20

Q1
W
65.8
1
64.1
2
65.8
1
63.0
6
65.8
1
65.8
1

Q2
W

Q
W

Nu

64.12

64.97

21.29

63.37

63.75

23.5

62.31

64.06

23.61

61.77

62.42

27.61

65.56

65.69

30.59

63.21

64.51

31.7

0.00606
4

1991

50

0.00693

2275

50

1.3
4
1.3
6

37.
9
38.
1

40.
5
40.
2

35.1

37.7

38.3

41.7

43.1

44.3

40

65.3
3

34.9

37.7

38.3

41.6

42.9

44

39.9

66.3

Table 6.4 Experimental friction factor test data for plain tube
Run
No.
1
2
3
4
5
6
7

m
ks/s
0.00267
0.00333
0.00422
0.00489
0.00556
0.00622
0.00711

v
m/s
0.14503
0.18129
0.22964
0.26589
0.30215
0.33841
0.38675

Re
872
1090
1380
1598
1816
2034
2325

21

h
m
0.02
0.03
0.04
0.04
0.04
0.05
0.05

p
Pa
197.33
295.995
394.66
394.66
394.66
493.325
493.325

f
0.0754
0.07238
0.06015
0.04487
0.03474
0.03462
0.02651

65.74

65.54

36.24

60.68

63.49

37.44

Table 6.5 Experimental friction factor test data for tube with WC1
Run
No.
1

m
ks/s
0.00267

2
0.00333
3
4
5

0.00422
0.00489
0.00556

6
0.00622
7
0.00711

v
m/s
0.1444
4
0.1805
4
0.2286
9
0.2648
0.3009
1
0.3370
2
0.3851
6

Re

h
m

p
Pa

876

0.04

392.4

0.15205

1095

0.05

490.5

0.12164

1386
1605

0.06
0.07

588.6
686.7

0.09097
0.07916

1824

0.09

882.9

0.07882

2043

0.08

784.8

0.05585

2335

0.09

882.9

0.04811

Table 6.6 Experimental friction factor test data for tube with WC2
Run
No.
1

m
ks/s
0.00267

2
0.00333
3
4
5

0.00422
0.00489
0.00556

6
0.00622
7
0.00711

v
m/s
0.1444
4
0.1805
4
0.2286
9
0.2648
0.3009
1
0.3370
2
0.3851
6

Re

h
m

p
Pa

876

0.06

588.6

0.22807

1095

0.07

686.7

0.17029

1386
1605

0.11
0.14

1079.1
1373.4

0.16679
0.15833

1824

0.14

1373.4

0.12261

2043

0.16

1569.6

0.11171

2335

0.16

1569.6

0.08553

22

6.2 Heat transfer characteristics

Fig. 6.3 shows the variation of Nusselt number with the variation in Reynolds number. It is
evident from the Figure that the heat transfer is enhanced with wire coil insert WC1 and further
increased when wire coil insert WC2 is used. The increase in heat transfer increases with
increase in Reynolds number. The heat transfer is increased by a factor of 1.27 and 1.47 with
WC1 and WC2 respectively. The results illustrate that the predicted turbulence intensity of wire
coil insert is higher than the plain tube. This can be the reason that more heat transfer rate is
obtained by wire coil insert than the plain tube.

Fig. 6.3 Variation of Nusselt number with the variation in Reynolds number for WC1.

Fig. 6.4 Variation of Nusselt number with the variation in Reynolds number for WC2.
6.3 Friction factor characteristics
Fig. 6.5 shows the variation of friction factor with the variation in Reynolds number. It is evident
from the Figure that the friction factor is enhanced with wire coil inserts. The friction factor is
increased by a factor of 0.8 and 2.4 with WC1 and WC2 respectively. This implies that use of
wire coil insert may be both beneficial and unbeneficial. Hence wire coil insert can be used for
heat transfer augmentation with caution.

23

Fig. 6.5 Variation of friction factor with the variation in Reynolds number
6.4 Performance ratio
Thermal performance factor is generally used to evaluate the performance of different inserts
under a particular fluid flow condition. It is a function of the heat transfer coefficient, the friction
factor and Reynolds number. For a particular Reynolds number, if an insert device can achieve
significant increase of heat transfer coefficient with minimum raise of friction factor, the thermal
performance factor of this device is good i.e., the ratio will be greater than 1. Thus in order to
justify the use of any insert or technique to increase the heat transfer rate, the performance ratio
must be greater than 1.

Fig. 6.6 Variation of performance factor with the variation in Reynolds number
Fig. 6.6 shows the variation of performance factor with the variation in Reynolds number. It is
evident from the Figure that the performance factor is greater than 1 for all values of Reynolds
number for laminar flow. However at very low Reynolds number there is no difference in the
performance factor of WC1 and WC2 but at Reynolds number greater than 1250, the
performance factor of WC1 is greater than WC2. This is because the friction factor is increase by
a factor of 2.4 with WC2 while the increase is only 0.8 with WC1. Hence it is concluded that the
favourable operating regime is when the Reynolds number is less than 1250 with wire coil insert
having a higher pitch ratio.

24

7. Conclusion
The effect of wire coil inserts on the heat transfer and pressure drop performance of
water under laminar flow with constant heat flux is experimentally investigated. The
following conclusions were drawn from the present work
The heat transfer is increased by a factor of 1.27 and 1.47 with WC1 and WC2
respectively. The results illustrate that the predicted turbulence intensity of
wire coil insert is higher than the plain tube. This can be the reason that more

heat transfer rate is obtained by wire coil insert than the plain tube.
The friction factor is increased by a factor of 0.8 and 2.4 with WC1 and WC2

respectively.
The performance factor is greater than 1 for all values of Reynolds number for
laminar flow. However at very low Reynolds number there is no difference in
the performance factor of WC1 and WC2 but at Reynolds number greater than
1250, the performance factor of WC1 is greater than WC2. It is concluded that
the favourable operating regime is when the Reynolds number is less than
1250 with wire coil insert having a higher pitch ratio.

References

25

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27