CCC

Mechanical System Design, 16 Dec 2016
Universiti Malaysia Pahang, Pekan, Malaysia
FACULTY OF MECHANICAL ENGINEERING
MECHANICAL SYSTEM DESIGN

BMM 4623
INDIVIDUAL PROGRESS REPORT
Design and Development of Two Flow Heat Exchanger Test Rig
Personal Progress Report
PREPARED BY: FONG WEI JUN MA13094

GROUP 05
PROJECT SUPERVISOR: DR. KUMARAN A/L KADIRGAMA

DESIGN AND DEVELOPMENT OF TWO FLOW HEAT EXCHANGER TEST RIG

W. J. Fong1 (MA13094)
Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP),
26600 Pekan, Pahang, Malaysia, Phone: +6094246255; Fax: +6094246222
1
Email: MA13094@stdmail.ump.edu.my, 1Phone: +60179015986
1.0 ABSTRACT
This project is to design and fabricate a two flow heat exchanger test rig that fulfil the
requirement of the course of BMM4623 Mechanical System Design. The heat exchanger
designed is a device that used to transfer heat between two type of fluids from high temperature
to low temperature and two type of fluids used are separated by a solid wall to prevent mixing or
direct contact with each other. In our project, the experiment is carried out by passing hot water
in inner copper pipe while cold water is passing through outer pipe. Initially we designed a
model of frame and heat exchanger, followed by carry out stimulation of heat transfer analysis at
heat transfer zone of hot water and cold water by using SOLIDWORKS 2016. Then, we did
finite analysis of the frame by using Autodesk Stimulation to find the maximum stress
concentration in order to prevent the frame from cracking, structural failure and fracture. It
followed by fabricating the frame by welding process and assembling the parts of copper tubes,
fittings, valves, pump and boiler. Then, we continued to attach sensors such as four
thermocouples and flow sensors that have been programmed and calibrated at various location of
the heat exchanger. The heat exchanger test rig developed is ensured to function properly by
carrying out experiment of parallel and counter flow, the overall heat transfer coefficient is
analyzed and compare for theoretical and actual case. The overall outcome of this project is
seemingly an evident for the completion and success of this project to design and develop a two
flow heat exchanger test rig.
Keywords: Double pipe heat exchanger; two flow; test rig
2.0 INTRODUCTION
The prerequisite of the course of BMM4623 Mechanical System Design in Universiti Malaysia
Pahang are BMM1532 Statics, BMM1533 Strength of Materials 1, BMM 2582 Strength of
Materials 2 and BMM 3623 Mechanial Design. The strong foundation that established in
prerequisite subjects enables students to equipped with solid theories and fundamental about
factor of safety, decision of type of materials used, structural forces and the application of
different type of softwares to design and fabricate two flow heat exchanger. Hence, prerequisite
subjects play an important role to build strong foundation to design, develop and fabricate an
engineering equipment [2, 3]. Before fabricating a heat exchanger, the appropriate design and
selection of materials is utmost important to prevent tube failure of heat exchanger that might
cause heavy maintenance and loss of production of a factory [4]. Moreover, stress analysis of an
2

equipment by using software before fabricating can prevent structural occur from happening [5].
Apart from that, Computational Fluid Dynamics is the stimulation experiment by running the
virtual design without any physical model which have been carried out by numerous engineering
application that can greatly reduce the cost [6].
Heat exchanger is a device to exchange heat of two moving fluids from high temperature fluid to
low temperature fluid without mixing those liquids [1]. common types of heat exchanger
application are evaporator, condenser, boiler and steam generator [7]. Heat exchangers also
greatly used in chemical and power plant sector as well as process industries [8, 9]. The design
and construction of heat exchangers varies with different purpose of uses. The components of
heat exchangers included heat transfer elements such as core that contains heat transfer surface,
inlet and outlet pipe, manifolds and tanks. The most crucial part is the heat transfer surface which
has direct contact with moving fluids and heat is transferred through conduction [10]. However,
for our case, our components of heat exchanger include four K-type thermocouple sensors, two
flow sensors, copper pipes, fittings, valves, pump and boiler with the function of adjustable
temperature. The heat transfer between two different temperatures in double pipe heat exchanger
is through conduction and convection method [11]. The hot water transfer heat by convection to
the tube wall, then conduction takes place across the tube to the opposite wall. The heat is then
convectively transferred to the second fluid [12]. The temperature of the fluid is not constant
through the exchanger as this process happens over the entire length of the exchanger. The rate of
heat transfer keeps changing along the exchanger tube as it depends on the temperature
difference hot and cold liquid at the point being viewed [13].
For this project, a concentric double pipe heat exchanger is designed and fabricated. Two types
of flow arrangement made possible for this type of heat exchanger which are parallel flow and
counter as shown in Figure 1 and Figure 2 [1]. In parallel flow, both hot and cold fluid enters
heat exchanger at the same end and move in the same directions. In counter flow however the hot
and cold fluid move in opposite direction and enters from opposite ends.[14]
Figure 1: Parallel flow[1]

Figure 2: Counter flow[1]
There are many effective methods and techniques to enhance heat transfer coefficient in heat
exchanger such as utilizations of design methods and usage of nanofluid solutions [15]. The heat
transfer rate can be enhanced by using water based nanofluids such as TiO 2, Zro2 and Al203 [16].
3

Many researchers have argued when volume concentration of Al 203 nanofluids increases, it
indicates the increment of heat transfer coefficients of nanofluids in the range of 12 to 15%, and
thus the thermal conductivity is enhanced [17]. Besides, it was found that heat transfer
coefficient is increased by 24.6% with the 60:40 (W:EG) ratio of Al2O3 base mixture [18]. From
the previous research, it is concluded that the best performance with twisted tape inserted into
annulus of double pipe heat exchanger is obtained at twist angle 45 0 due to more swirl and
turbulence induced by tape insert that for counter flow and the highest increase in pressure drop
resulted for 450 twisted tape compared to 600 twisted tape [19]. Apart from that, the creation of
an annular region within the inner pipe by simulation indicates the increment of heat transfer
efficiency the required heat exchanger length is reduced by almost 25% [20]. . The theoretical
analysis shows that addition of an intermediate pipe to the double pipe heat exchanger decreases
effective length of heat exchanger, which results in savings in material and space[21, 22]. The
triple concentric pipes heat exchanger provides large heat transfer area per unit heat exchanger
length and better heat transfer efficiencies compared to double pipe heat exchanger[23]. In
addition, the heat transfer coefficient performance of helical coil typed heat exchanger is higher
than straight tube typed heat exchanger [24].
The purpose of this project is to design and develop a new two flow heat exchanger and to
determine the rate of heat transfer and the overall heat transfer coefficient for both parallel flow
and counter flow.
3.0 OBJECTIVES
The objective of this project are as follows:
i.
ii.
iii.
To compare the rate of heat transfer of parallel and counter flow for theorectical and
actual condition
To design and fabricate a two flow heat exchanger using engineering knowledge
To improve the rate of heat transfer and efficiency of heat exchanger
4.0 METHODOLOGY
Copper pipe is selected as the materials to fabricate heat exchanger due to its high heat
conductivity, k= 401 W/(mK) and resistance to corrosion [25] which has greater heat transfer
coefficient compare to other materials. Mild steel bar is used as the materials of test rig frame
due to its high toughness, ductile, low cost, high ultimate tensile strength (841 MPa) and
malleable characteristic that can withstand high loading on it [26]. To join the test rig frame,
shielded metal arc welding (SMAW) because it can be used in areas which have limited access
and tiny position which can effectively weld the joint areas, and its operating procedure is simple
and inexpensive [27]. K-type of thermocouples are used as the temperature sensor in our project
because this type of temperature sensor can detect the range of temperature between 0 oC to
1023oC [28] and it can contact with liquid which fulfilled the parameters set by our project.
Moreover, the temperature sensors are calibrated to achieve the high accuracy in taking readings
[29]. The flow sensor used is SBS-H2 21WA with working range between 1 to 30L/min of fluid
flow that within the range of our project. The K-type thermocouples and flow sensors are
connected to a designed circuit before connecting to Arduino Uno which acts as interface to
4

convert analog signal to digital data that is readable by human [30]. In addition, in order to
lubricate the connections between copper pipe and fittings as well as to screwed them deeper
together, PTFE tape is applied at the joint section [31]. Brazing method is applied to join the
copper pipes and fittings together to prevent leakage because brazing allows much tighter control
over tolerances and produces a clean joint without the need for secondary finishing. Moreover,
brazing method produce less thermal distortion than welding due to the uniform heating of a
brazed piece [32].
START
GROUP
FORMATION AND
PROPOSAL
SUBMISSION
DESIGNNING
AND MODELLING
STIMULATION ANALYSIS
FAIL
PASS
PURCHASE OF
MATERIAL
FABRICATION

ASSEMBLY
ARDUINO
CODING,
TESTING AND
PRODUCT
TESTING AND
EXPERIMENT
POSTER AND
P
FULL REPORT
PREPARATION
FINAL
PRESENTATION
END
4.1 DESIGN
6

First and foremost, the schematic diagram of two flow heat exchanger with test rig frame of
correct dimensions and appropriate type of materials used is drawn by using SOLIDWORKS
2016. The orthographic view which involved top view, front view and side view of test rig frame
is as shown in Figure 3 and the drawing of heat exchanger test rig which include components
such as pump, boiler, copper pipe connection network is as shown in Figure 4 below. The
dimension of frame designed is 1-meter-long x 1-meter-width x 2-m-height which is made of
1.5-inch x 1.5-inch hollow mid steel square bar.
.
Figure
3:
Orthographic view of test rig frame:

Figure 4: SOLIDWORKS drawing of double pipe heat exchanger

4.2 COMPUTATIONAL FLUID DYNAMICS ANALYSIS
The completed SOLIDWORKS drawing is transferred to SOLIDWORKS Flow
Simulation program to analyze the simulation of the transfer zone of heat exchanger. The heat
transfer zone refers to section where heat is transferred from hot water to cold water. Since our
project comprises two flow; counter flow and parallel flow. Therefore, the analysis is performed
twice by using different type of flow of fluids.
The heat exchange section for the analysis comprises 1-meter-long of tube-in-tube setup
of 22 mm diameter and 15 mm diameter copper tube. The virtual situation of conduction and
convection are analyzed before the real test rig is fabricated to test the functionality, workability
and efficiency of the heat exchanger we designed.
For the analysis, the parameter we set for temperature of hot water inlet is 60 oC, due to
the limitation of pump which can operate within 60 oC. For cold water, the temperature we set
25oC which is the temperature of incoming tape water. The gate valves are adjusted to ensure the
volume flow rate, V of five liters per minute for both cold water and hot water respectively.
Mass flow rate of cold water and hot water is obtained by the formula of
m
= V
(1)
8

Therefore, mass flow rate of both hot and cold water are set to 83.33 kg/s. The results of analysis
for both parallel flow and counter flow is as shown in Figure and Figure.
The parameters set for CFD stimulation:
I.
II.
III.
IV.
Temperature of hot water: 60oC

Temperature of cold water: 25oC
Mass flow rate of hot water: 83.33 kg/s
Mass flow rate of cold water: 83.33 kg/s
4.2 FINITE ELEMENT ANALYSIS

The STEP file from SOLIDWORKS is imported into Autodesk Simulation Mechanical
2016 which is the software to do Finite Element Analysis (FEA) for the test rig frame. It
comprises the analysis of the displacement and the Von Mises Stress of frame structure.
The parameters set for FEA stimulation:
I.
II.
III.
IV.
100% mesh size (between fine and coarse mesh size)

Materials used: A36 Mild Steel
Force condition: 29.43N (3kg weight) in negative Y-direction (due to gravitational force)
Boundary condition: The base of the frame is fixed and no movement
Displacement analysis results of heat exchanger test rig is shown in Figure.

Figure : The displacement analysis of heat exchanger test rig

The maximum displacement is 0.0583 mm which is the joint part of 1.5-inch x 1.5-inch of
hollow mild steel by arc welding process that located at the top of frame. While the minimum
displacement is 0 mm at base (no deformation) due to the force that are equally distributed to
four side of the test rig frame. Overall, there is no deformation occurs because the maximum
displacement showed, 0.0583 mm is only 0.0029 % out of 2-meter height of test rig frame.
Therefore, the test rig frame is safe to use in term of deformation factor.
Von Mises Stress analysis results of heat exchanger test rig is shown in Figure.
10

Figure : The stress analysis of heat exchanger test rig

From Figure above, the maximum Von Mises Stress displayed is 13.5 MPa which is located at
the joining part of vertical and horizontal 1.5-inch x 1.5-inch of hollow A36 mild steel while the
minimum Von Mises Stress displayed is 76.79 Pa at the top edge of test rig frame. The area with
maximum Von Mises Stress indicates that the area has the greatest potential to be fracture. Since
ultimate strength of A36 steel is 400 MPa [33], the formula of factor of safety, F.S of the test rig
is
F.S =
Ultimateload
Allowable load
()
The factor of safety of 2.96 is safe enough to support whole test rig frame without failure of
structure.
Since both the results from displacement and Von Mises Stress indicate the design of our heat
exchanger test rig fulfilled the criteria without causing deformation, cracking or fracture,
therefore fabrication procedure is proceeded.
11

4.3 FABRICATION
The material details of fabrication of heat exchanger test rig is listed as Table below.
No
Element
:
1
Four K-type thermocouples with MAX6675 interface chip
2
Two SEN-HZ21WA water flow sensor
3
Arduino UNO with cable
4
1m copper pipe with diameter of 21 mm outer diameter
5
9m copper pipe with 15mm outer diameter
6
DB-35 water pump with maximum height of 40m
7
Immersion heater with adjustable temperature controller
8
3 meters of rubber hose
9
Four ball valves
10 Two gate valves
11 Six elbow fittings
12 Six meters of 1.5 inch x 1.5 inch A36 steel hollow square bar
13 Four rollers
14 Seven brass elbow joints
15 Six meters if insulation materials
16 Twelve M6 bolts and nuts
17 1.6 m x 1m galvanized sheet metal with 1 mm thickness
18 Thermometer
Table : List of materials used
Fabrication of two flow heat exchanger test rig included many machining process such as arc
welding, brazing, drilling, surface finishing, wiring, programming and so forth. The machining
processes are based on consideration of fluid properties, size and diameter of thermocouples,
material properties, user-friendliness and so forth.
4.3.1 HEAT EXCHANGER NETWORK
The most important part is the place where heat transfer between hot water to cold. For this part,
inner tube, the path where hot water flowing through is 1.3m with outer diameter of 15mm and it
is covered by 1m length of copper tube with 21mm outer diameter is acted as outer pipe which
act as the path where cold water flowing through. Two reducing couplings and two T-joints were
used to connect both pipes with different diameters.
After assembling the who heat exchanger, all the separated parts of copper tubing are connected
by brazing process as shown in Figure. During brazing process, copper filler is used to join two
parts and flux powder is used to prevent oxidation of the copper and filler materials. Then, it
followed by drilling process on heat exchanger surface for installation of temperature sensors. In
addition, adhesion glues were also used to join some of the connection to prevent leakage. The
copper pipes are insulated to prevent heat loss. The gate valves are assembled to the flow meter
sensor to control the volume flow rate of the water. The assembly process of copper pipe network
is as shown in Figure.
12

4.3.2
RIG
TEST
FRAME:
The fabrication of test rig frame involved cutting process, arc welding, shearing. First of all, all
the 1.5-inch x 1.5-inch hollow mild steel square bar are cut into designed dimension by miter
saw. Then, the sand paper is used to remove oxide layer on surface of hollow bar. The hollow
bars are joined by arc welding process followed by surface finishing by grinder. Then, the test rig
frame is sprayed to black colour to enhance esthetical value and to reduce corrosion rate from
happening. Then, the base of hollow mild steel square bar is drilled and rollers are installed with
bolts and nuts. The process of fabrication of frame is as shown in Figure.
13

4.4 CODING AND CALIBRATION

Four K-type thermocouple were used to detect the temperature change at four different locations
where the entrance and exit of hot water as well as the entrance and exit of cold water. Type-K
Thermocouple is simply made by two metal wires which are nickel and chromium. They used to
measure the voltage across the wires by using the relationship; the higher the temperature, the
higher the voltage. However, it is hard to detect the small changes in voltage difference.
Therefore, thermocouple interface chip, MAX6675 is connected to K-type thermocouple to
amplify the voltage difference across it as shown in Figure 6. The MAX6675 performs coldjunction compensation and digitizes the signal from a K-type thermocouple. The flow sensors
used to measure flow rate of cold water and hot water is SBS-H2
21WA as shown in Figure 7. The coding is run in Arduino
software.
Figure 6: K-type thermocouple with MAX6675 interface chip
14

Figure: Configuration of circuit connection of sensors in break board

Two flow sensors are connected in digital pin 2 and pin 3 of Arduino Uno board due
to the function of Interrupt as instructed by Arduino official website. Interrupt
function are useful in solving timing problem that may include reading a rotary encoder
of flow sensor. It can insure that a program always caught the rotarys encoder pulses
immediately without waiting for the code to run line by line.
MAX6675 chips of K-type thermocouples are freely to connected to any slots in digital pin of
Arduino board. This is due to the uses of Arduino library for interfacing with MAX6675
thermocouple amplifier that can easily interface with a MAX6675 chip via its Serial Peripheral
15

Interface (SPI) interface. There are five pins in MAX6675 which include SO pin, CS pin, SCK
pin, VCC pin and GND pin. Each pin has its own function as listed below:
Pin
SO (Serial Output)
CS (Chip Select)
SCK (Serial Clock)
VCC
GND
Function
Arduino reads signal from the pin
To select the Module and supply an output
that is synchronize with a clock
Input from Arduino
Voltage supply (5V)
Ground
All the connections are clearly to be seen in schematic diagram of Figure . The schematic
diagram is drawn by using Fritzing software.
16

Figure : Schematic diagram of connection of circuit by using Fritzing software

4.5 CALIBRATION
All sensors are subjected to noise, hysteresis and other disturbances that might alters the
accuracy, precision and resolution of sensors in data taking. Therefore, calibration of sensors is
compulsory in order to increase signal to noise ratio. For this project, testing and calibration of
temperature sensors and flow sensors were done on a break board before soldering into Donut
board. We referred to boiling point of water;100 0C and melting point of ice, 0 0C to do calibration
in order to achieve highest accuracy of readings. Then, we refer to the formula of
Corrected value. X = (
Raw ValueRaw Low

Raw range
)(Reference Range)+ Reference Low
(1)
Where
(2)
Reading
display
by
sensor
after
calibration
Raw value = Reading display by sensor before calibration

(3)
Raw low = Reading display by sensors after direct contact with ice, 0oC
(4)
Raw range= Raw high Raw low
(5)
= Sensor reading after contact with boiling water sensor reading after contact with ice
(6)
Reference Range = Reference high Reference low
(7)
= Boiling point of water, 100oC melting point of ice, 0oC
(8)
The process to contact K-type thermocouples to boiling water and ice is as shown in Figure.
17

Figur
e: Two points calibration of K-type thermocouple by attaching to ice and boiling water
The flow sensors are calibrated by comparing the digital value to manual calculation. For manual
calculation, kettle with 1.5 liter of water is prepared and poured through the sensor. Time is
measured at the moment 1.5 liter of water completely poured through the sensors. The manual
calculated flow rate, Q is calculated by the formula:
Q=
volume of water pass through sensor mL

time taken
min
(9)
Then, it is compared with the digital value displayed. Flow calibration factor of flow sensor is
adjusted so that the manual calculated flow rate is same with digital value displayed by Arduino.
The coding is attached in Appendix.
18

Figure
User
7:
interface for Arduino software

The two flow heat exchanger test rig is completely fabricate as shown in Figure below.
5.0 EXPERIMENTAL PROCEDURE:

19

a) The configuration of the heat exchanger is set as parallel flow and the cool water pipe is
turned on.
b) The temperature controller is adjusted to 60 0C and the water inside boiler is heated to
achieved 60 0C.
c) The water flow rate for both hot and cold water is set as 5 liter/min by adjusting gate
valve.
d) The Arduino which consists of four temperature sensors, two flow sensors, Arduino UNO
hardware and the computer with Arduino software is turned on and cable is connected to
computer.
e) The temperature displayed on computer is recorded and analysed.
f) Step a to e is repeated by changing the flow configuration of heat exchanger from parallel
flow to counter flow.
g) The heat transfer rate is to be determined for both parallel and counter flow by using log
mean temperature method.
RESULTS AND DISCUSSION
CFD ANALYSIS
Parallel Flow:
Figure 6: Analysis of parallel flow arrangement.
Type of fluid
Inlet Temperature
(oC )
Outlet Temperature
(oC )
Temperature
change
20

Hot water
Cold water
Counter Flow:
60
25
(oC )
30.48
3.94
29.52
28.94
Figure 6: Analysis of counter flow arrangement.

Type of fluid
Hot water
Cold water
Inlet Temperature
( oC )
60
25
Outlet Temperature
( oC )
25.24
28.96
Temperature change
(oC )
34.76
3.96
From the stimulation, it is found that the heat transfer of counter flow is more efficient than
parallel flow. For parallel flow, the temperature change of hot water is 50.8% and temperature
change for cold water is 15.76%. For counter flow, the temperature change of hot water is
57.93% and temperature change for cold water is 15.84%.
The heat transfer rate is determined by log mean temperature difference method, Tlm, where
T 1 T
T
ln( 1 )
T2
Tlm =
()
For parallel flow,
21

T1 = Th, in Tc, in
()
T2 = Th, out Tc, out
()
T1 = Th, in Tc, out
()
T2 = Th, out Tc, in
()
For counter flow,
Heat transfer rate, Q is expressed as
Q
= UAsTlm
()
Whrere,
U is overall heat transfer coefficient (W/m2.K)
As is surface area of heat transfer (m2)
Flow
arrangement
Hot water ( oC)

Th,in
Th,out
Cold water ( oC)

Tc,in
Tc,out
Tlm
( oC)
Parallel flow
55.30
36.42
25
28.64
16.56
Heat Transfer
Rate
(W/m2.K)
0.47
Counter flow
55.42
39.61
25
32.43
29.45
0.83
22

Figure:
Graphs
temperature
parallel and counter
of
gradient for both
flow
The graph
of
are
temperature gradient against location
displayed for both

parallel and
counter flow. The
heat transfer coefficient, U
used is 1000
W/m2.K for
water to water
type of
heat
exchanger.
Based on
the results
obtained, the rate of heat transfers of counter flow, 0.83 W is greater than 0.47 W by 76.6 %.
7.0 CONCLUSION
In a nutshell, the objectives are achieved and we manage to design and fabricate a two flow heat
exchanger test rig. Finite Element Analysis and Computational Fluid Dynamic analysis are
important to make sure the heat exchanger test rig can work properly without fracture and failure
and achieved the required factor of safety. Log mean temperature difference method is used to
measure the rate of heat transfer. The heat transfer rate of counter flow;0.83 W is greater than
parallel flow; 0.47 W by 76.6%.
ACKNOWLEDGMENTS
The author would like to thank Universiti Malaysia Pahang for their financial support and
laboratory equipment and materials. The author also thanks Dr Muhamad Bin Mat Noor and Dr
Kumaran A/L Kadirgama for the guidance and advices.
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Whitehouse, K. and D. Culler. Calibration as parameter estimation in sensor
networks. in Proceedings of the 1st ACM international workshop on Wireless
sensor networks and applications. 2002. ACM.
Badamasi, Y.A. The working principle of an Arduino. in Electronics, Computer
and Computation (ICECCO), 2014 11th International Conference on. 2014.
IEEE.
Gore, W.L., Sealing material. 1972, Google Patents.
Boam, W.M. and H.H. Hanink, Method of copper brazing. 1957, Google
Patents.
Beer, F., Statics and mechanics of materials. 2016: McGraw-Hill Higher
Education.
Appendices:
Arduino coding
#include "max6675.h"
byte statusLed = 13;
const byte sensorInterrupt1 = 0; // 0 = digital pin 2
const byte sensorPin1
= 2;
const byte sensorInterrupt2 = 1; // 0 = digital pin 2
const byte sensorPin2
= 3;
25

float calibrationFactor1 = 4.5;

volatile byte pulseCount1;
float flowRate1;
unsigned int flowMilliLitres1;
unsigned long totalMilliLitres1;
unsigned long oldTime1;
float calibrationFactor2 = 4.5;
volatile byte pulseCount2;
float flowRate2;
unsigned int flowMilliLitres2;
unsigned long totalMilliLitres2;
unsigned long oldTime2;
int thermoDO1 = 8;
int thermoCS1 = 4;
int thermoCLK1 = 9;
int thermoDO2 = 8;
int thermoCS2 = 5;
int thermoCLK2 = 9;
int thermoDO3 = 8;
int thermoCS3 = 6;
int thermoCLK3 = 9;
int thermoDO4 = 8;
int thermoCS4 = 7;
int thermoCLK4 = 9;
MAX6675 thermocouple1(thermoCLK1, thermoCS1, thermoDO1);
void setup() {
Serial.begin(9600);
// use Arduino pins
pinMode(statusLed, OUTPUT);
digitalWrite(statusLed, HIGH); // We have an active-low LED attached
pinMode(sensorPin1, INPUT);
26

digitalWrite(sensorPin1, HIGH);
pinMode(sensorPin2, INPUT);
digitalWrite(sensorPin2, HIGH);
pulseCount1
= 0;
flowRate1
= 0.0;
flowMilliLitres1 = 0;
totalMilliLitres1 = 0;
oldTime1
= 0;
pulseCount2
= 0;
flowRate2
= 0.0;
flowMilliLitres2 = 0;
totalMilliLitres2 = 0;
oldTime2
= 0;
attachInterrupt(sensorInterrupt1, pulseCounter1, FALLING);
Serial.println("MAX6675 test");
// wait for MAX chip to stabilize
delay(500);
}
void loop() {
// basic readout test, just print the current temp
if((millis() - oldTime1) > 1000) // Only process counters once per second
{
detachInterrupt(sensorInterrupt1);
flowRate1 = ((1000.0 / (millis() - oldTime1)) * pulseCount1) / calibrationFactor1;
oldTime1 = millis();
flowMilliLitres1 = (flowRate1 / 60) * 1000;
totalMilliLitres1 += flowMilliLitres1;
unsigned int frac1;
// Print the flow rate for this second in litres / minute
Serial.print("Flow rate1: ");
Serial.print(int(flowRate1)); // Print the integer part of the variable
Serial.print(".");
// Print the decimal point
// Determine the fractional part. The 10 multiplier gives us 1 decimal place.
frac1 = (flowRate1 - int(flowRate1)) * 10;
Serial.print(frac1, DEC) ;
// Print the fractional part of the variable
Serial.print("L/min");
// Print the number of litres flowed in this second
27

Serial.print(" Current Liquid Flowing1: ");

Serial.print(flowMilliLitres1);
Serial.print("mL/Sec");
// Output separator
// Print the cumulative total of litres flowed since starting

Serial.print(" Output Liquid Quantity1: ");
// Output separator
Serial.print(totalMilliLitres1);
Serial.println("mL");
// Reset the pulse counter so we can start incrementing again
pulseCount1 = 0;
// Enable the interrupt again now that we've finished sending output
}
if((millis() - oldTime2) > 1000) // Only process counters once per second
{
detachInterrupt(sensorInterrupt2);
flowRate2 = ((1000.0 / (millis() - oldTime2)) * pulseCount2) / calibrationFactor2;
oldTime2 = millis();
flowMilliLitres2 = (flowRate2 / 60) * 1000;
totalMilliLitres2 += flowMilliLitres2;
unsigned int frac2;
// Print the flow rate for this second in litres / minute
Serial.print("Flow rate2: ");
Serial.print(int(flowRate2)); // Print the integer part of the variable
Serial.print(".");
// Print the decimal point
// Determine the fractional part. The 10 multiplier gives us 1 decimal place.
frac2 = (flowRate2 - int(flowRate2)) * 10;
Serial.print(frac2, DEC) ;
// Print the fractional part of the variable
Serial.print("L/min");
// Print the number of litres flowed in this second
Serial.print(" Current Liquid Flowing2: ");
// Output separator
Serial.print(flowMilliLitres2);
Serial.print("mL/Sec");
// Print the cumulative total of litres flowed since starting
Serial.print(" Output Liquid Quantity2: ");
// Output separator
Serial.print(totalMilliLitres2);
Serial.println("mL");
28

// Reset the pulse counter so we can start incrementing again

pulseCount2 = 0;
// Enable the interrupt again now that we've finished sending output
}
Serial.print("C1 = ");
Serial.print(thermocouple1.readCelsius());
Serial.print(" ");
Serial.print(" ");
Serial.print(" ");
Serial.println(thermocouple4.readCelsius());
delay(1000);
}
void pulseCounter1()
{
// Increment the pulse counter
pulseCount1++;
}
void pulseCounter2()
{
// Increment the pulse counter
pulseCount2++;
}
29

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Mechanical System Design, 16 Dec 2016

Universiti Malaysia Pahang, Pekan, Malaysia

FACULTY OF MECHANICAL ENGINEERING

MECHANICAL SYSTEM DESIGN

Personal Progress Report

PREPARED BY: FONG WEI JUN MA13094

PROJECT SUPERVISOR: DR. KUMARAN A/L KADIRGAMA

Mechanical System Design, 16 Dec 2016

DESIGN AND DEVELOPMENT OF TWO FLOW HEAT EXCHANGER TEST RIG

Mechanical System Design, 16 Dec 2016

Figure 1: Parallel flow[1]

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Orthographic view of test rig frame:

Mechanical System Design, 16 Dec 2016

Figure 4: SOLIDWORKS drawing of double pipe heat exchanger

Mechanical System Design, 16 Dec 2016

Temperature of hot water: 60oC

4.2 FINITE ELEMENT ANALYSIS

100% mesh size (between fine and coarse mesh size)

Displacement analysis results of heat exchanger test rig is shown in Figure.

Mechanical System Design, 16 Dec 2016

Figure : The displacement analysis of heat exchanger test rig

Mechanical System Design, 16 Dec 2016

Figure : The stress analysis of heat exchanger test rig

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

4.4 CODING AND CALIBRATION

Figure 6: K-type thermocouple with MAX6675 interface chip

Mechanical System Design, 16 Dec 2016

Figure: Configuration of circuit connection of sensors in break board

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Figure : Schematic diagram of connection of circuit by using Fritzing software

Raw ValueRaw Low

)(Reference Range)+ Reference Low

Raw value = Reading display by sensor before calibration

Mechanical System Design, 16 Dec 2016

volume of water pass through sensor mL

Mechanical System Design, 16 Dec 2016

interface for Arduino software

5.0 EXPERIMENTAL PROCEDURE:

Mechanical System Design, 16 Dec 2016

Figure 6: Analysis of parallel flow arrangement.

Mechanical System Design, 16 Dec 2016

Figure 6: Analysis of counter flow arrangement.

Mechanical System Design, 16 Dec 2016

T2 = Th, out Tc, out

T1 = Th, in Tc, out

T2 = Th, out Tc, in

For counter flow,

Heat transfer rate, Q is expressed as

Hot water ( oC)

Cold water ( oC)

Mechanical System Design, 16 Dec 2016

temperature gradient against location

displayed for both

Mechanical System Design, 16 Dec 2016

Mechanical System Design, 16 Dec 2016

Prabhanjan, D.G., G.S.V. Raghavan, and T.J. Rennie, Comparison of heat