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STANDARD OPERATION PROCEDURES

PLANT START-UP PROCEDURE

The following is a start-up checklist with preliminary exercises. Please go through them before
starting any Experiment. Also refer to the P and I sketch in the Manual.

1. Switch on the main power supply to the Plant at the front of the panel.
WHENEVER ANY ANNUNCIATOR IS ACTIVATED, PRESS THE ACKNOWLEDGE
(RED) BUTTON TO SILENCE THE BUZZER. RATIONALISE THE CAUSE OF THE
ALARM CONDITION.
2. Switch the DP Selector Switch to the equalizing (vertical or 0) position.
3. The manual valve at the external water supply inlet to T1 should always be opened.
4. Fill tank T1 and T2 with water to their maximum level.
5. At tank T1, shut fully the discharge valve (HV) but open fully its by-pass valve (BVH). Start
the HW pump PH for the water recirculate around its tank T1, via only BVH. The suction valve
of pump PH must remain open at all times.
6. Switch ON the heaters from the front of the panel and allow the water in tank T1 to be heated to
its maximum temperature 70C (see TIC5).
7. Check that all the CW pumps (PC1, PC2) by-pass valves (BVC1, BVC2) and discharged valves
(CV1, CV2) are opened. All suction valves for pumps PC1, PC2 and PH must remain open at
all times.
8. Make sure CW pumps PC1 and PC2 are off. Note that the HW pump PH is still recirculating
HW around its tank T1 via its by-pass valve (BVH), but its discharge valve (HV) is still fully
shut.
9. Quickly check the various manual valves as follows:-
The manual by-pass valves around the control valves TSV3A and TSV3B should be always
shut but their adjacent manual valves should be always opened.
The bottom manual drain valves of tank T1 and T2 are always shut.
10. For details of the Experiments to be conducted, please refer to the Plant Experiment Manual of
MODEL HE12.

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AIM OF EXPERIMENTS:
To evaluate and study the performance of the Shell and Tube Heat Exchanger at various
operating conditions.

PART I : Heat Load and Heat Balance

LMTD, Overall Heat Transfer Coefficient U.

PART II : Turbulent/Laminar Flow

Reynolds Number Shell Side
Reynolds Number Tube Side

PART III : Heat Transfer Coefficients

PART IV : Pressure Drop

Shell Side
Tube Side

A) DESCRIPTION OF EQUIPMENT
The major equipment are as follows :-

I. SHELL AND TUBE HEAT EXCHANGER

The Heat Exchanger operates with heated water HW (70oC, 158oF max*) as the heating
medium at the Tube-side and ambient or warm water CW at the Shell-side.

II. HEATING MEDIUM HW TANK

Familiarize with the various equipment and instruments but do not operate any
equipment yet.

i. The hot water tank T1 must be filled with water up to its maximum level - the level of
its overflow drain pipe (D).

ii. An electric immersion heater in tank T1 is automatically switched off by an ON/OFF

controller TIC5 when the heated water exceeds 70oC.
There will be a slight overshoot in the water temperature after the heater is switched
off.

iii. Pump PH circulates the hot water (heating medium) HW into the tube-side of the
Heat Exchanger and then returns it to tank T1. The pump should always be started
only when the water level in tank T1 is near its maximum level and its by-pass valve
(BVH) fully opened.

iv. The flowrate of HW to the Heat Exchanger can be manually regulated at the by-pass
valve (BVH) with the discharge valve (HV) fully opened.

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v. The process conditions of the heating medium HW are monitored as follows :-

HEATING MEDIUM HW, Heat Exchanger Tube-side

Process Variables Instrumentation
Flowrate, USGPM, FH FI(H)*
Pressure, psig, Inlet to Heat Exchanger PG-H
Temperature, C, Inlet, t1 TI1*
TI2*
Temperature, C, Outlet, t2
DPI*
Pressure Drop, mm Water, DP (Tube)
NOTE*: Asterisked (*) instruments are panel-mounted.

III. COLD WATER CW TANK

Familiarize with the various equipment and instruments but do not operate any
equipment yet.

i. The larger tank is the cold water CW tank T2.

ii. The maximum cold water level in each tank is defined by its overflow drain pipe D.
External ambient water supply is permanently available to tank T2 and this inflow is
controlled by a mechanical float and valve to ensure that its level will be maintained at
its maximum level.

iii. CW heated at the shell-side of the Heat Exchanger returns to tank T2, so that the CW
in T2 becomes warm. Excess water in T2 overflows into the drain (D).

iv. There are two similar CW pumps PC1 and PC2 pumping CW to the shell-side of the
Heat Exchanger from T2, via their respective manual discharge valves CV1, CV2.
Both pumps are operated simultaneously. When only one CW pump is operated for
pumping CW into the Heat Exchanger, the other CW pump is operated as a back-
mixing pump with its manual discharge valve fully shut but its by-pass valve fully
opened. This is the usual mode of operation, with PC2 acting as the back-mixing
pump, and its discharge valve (CV2) fully shut but its by-pass valve (BVC2) fully
opened.

By manually regulating the by-pass valve BVC1, the flowrate of the CW from pump
PC1 to the Heat Exchanger can be varied. Note that both the pump suction valves for
PC1 and PC2 must remain always opened.

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v. The process conditions of the CW is monitored as follows :-

COLD WATER HW, Heat Exchanger Shell-side

Process Variables Instrumentation
Flowrate, USGPM, FC FI(C)*
Pressure, psig, Inlet to Heat Exchanger PG-C
Temperature, C, Inlet, T1 TI3(T1)/TIC3*
TI4*
Temperature, C, Outlet, T2
DPI*
Pressure Drop, mm water, DP (Shell)
NOTE*: Asterisked (*) instruments are panel-mounted.
TI3(T1)/TIC3* also acts as an ON/OFF controller to direct the CW from the Heat
Exchanger EITHER back to T2 (Open TSV 3A/Shut TSV 3B) OR to the Drain (Shut
TSV3A/Open TSV 3B), depending on the CW outlet temperature at TE3 (T1).

IV. INSTRUMENTATION

i. Flowrates, USGPM
The flowrates of CW and HW can be read from the panel-mounted digital Flow
Indicators, FI(C)* and FI(H)* respectively. These flowrates are transmitted from their
respective flowmeters FT(C) and FT(H).

The pumps should always be started with their respective by-pass valves fully open.
The flowrate required is then set by regulating its by-pass valve, with the pump
discharge valve remaining fully open. All pumps suction valves must remain fully
opened.

ii. Temperatures, oC
Temperature rise in CW due to heating at the Heat Exchanger is read from the
difference between the CW outlet (TI4*, T2) and inlet (TI3*, T1) temperatures.

Similarly, the temperature drop in HW is read from the difference between the HW
inlet (TI1*, t1) and outlet (TI2*, t2) temperatures.

The four temperatures are measured using Resistance Temperature Detector (RTD)
elements which are tagged as TE1, TE2, TE3 and TE4. Their temperatures are
displayed at the digital Temperature Indicators TI1*, TI2*, TI3* and TI4* respectively,
all mounted at the panel. TI3* is tagged TI3(T1)/TIC3* denoting that TI3 also
has ON/OFF control (TIC3) capabilities.

For each RUN of experiment (corresponding to pre-selected flowrates of CW i.e. FC

and HW i.e. FH), a few Sets of temperature readings are to be taken with changing
(usually decreasing) t1/t2. Each Set of temperature readings comprises reading T1, T2,
t1 and t2 simultaneously. The technique in getting good results is to be able to read the
changing T1, T2, t1 and t2 simultaneously, at almost steady-state conditions.

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By taking a few Sets of readings consecutively for each RUN, the best Set of
readings can be selected to represent the RUN. The criterion for selection is
the Heat Balance test where Heat gain QC converges best to equal Heat lost
QH.

iii. Pressure Drops, mm H2O; Pressures, psig

The pressure drop (DP) across the Heat Exchanger Shell side is read from the
difference between the inlet and the outlet pressure of the Heat Exchanger at its CW
pipeline, measured using a Differential Pressure Transmitter (DPT). The measured DP
signal is transmitted to the panel-mount indicator (DPI*). The Heat Exchanger Tube
side pressure drop is also measured using the same DPT and DPI*. A DP selector
switch is provided at the panel to select one at a time, the measurement and display of
the two pressure drops at the Shell and Tube sides viz either DP (Shell) or DP
(Tube) at the panel-mount DPI*.

There is a pressure gauge PG-C to measure the CW pressure at the inlet to the Shell-
side of the Heat Exchanger.

There is a pressure gauge PG-H to measure the HW pressure at the inlet to the Tube-
side of the Heat Exchanger.

Further note that the various pressure drop tapping points are not installed directly
inside the Heat Exchanger inlet/outlet ports, to avoid excessive turbulence. Note
therefore that each measured pressure drop is due to the Heat Exchanger PLUS those
of its inlet expansion and short pipe length AND outlet contraction and short pipe
length. The short pipe lengths include pipe elbows and Tees which also contribute to
pressure drop. The actual pressure drop due to the Heat Exchanger (Shell and Tube
sides) should be less than those indicated by these measurements i.e.
Actual DP(Tube) = Measured DP(Tube) at DPI* - DP due to the HW
piping between its tapping points and the HE
inlet/outlet HW ports, which can be calculated (see
Appendix section, CORRECTION TO THE
MEASURED DP(TUBE) AND DP(SHELL).
Actual DP(Shell) = Measured DP(Shell) at DPI* - DP due to the CW
piping between its tapping points and the HE
inlet/outlet CW ports, which can be calculated (see
Appendix section, CORRECTION TO THE
MEASURED DP(TUBE) AND DP(SHELL).

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B) PREPARATION PROCEDURES

Start the following preparation procedures step-by-step.

i. Fill tanks T1 and T2 with water to their maximum level, defined by their overflow drain
pipes D.

ii. At tank T1, shut fully the discharge valve (HV) but open fully its by-pass valve (BVH).
Start the HW pump PH for the water to recirculate around its tank T1, via only BVH. The
suction valve of pump PH must remain open at all times.

Switch ON the heaters at the front of the panel and allow the water in tank T1 to be
heated to its maximum temperature 70C /158F (see TIC5), which will take about 20
minutes. Whilst waiting, proceed to (iii) below. The ON/OFF temperature controller
TIC5 will automatically switch OFF the heaters in tank T1 when the heated water
temperature exceeds its preset High Limit (say 70C), and switch them ON again when the
temperature drops below, say 0.5 C of its preset High Limit (i.e. below 69.5C).

iii. CW System : Heat Exchanger Shell side

Meanwhile get familiar with the equipment, instrumentation, piping system and the various
manual valves. The following preliminary procedures are recommended for familiarization.
a) Check that all the CW pumps (PC1, PC2) by-pass valves (BVC1, BVC2) and discharge
valves (CV1, CV2) are opened. Note that the suction valves of all the pumps (PC1,
PC2 and PH) must remain open at all times.

b) Check that the external water supply to tank T2 is always available but is automatically
shut by the mechanical float-level valve at high level in tank T2.
Test the water availability by pushing down the float - water must flow into tank T2
via the float-level valve to confirm water availability.

c) Make sure the CW pumps PC1 and PC2 are off. Note that the HW pump PH is still
recirculating HW around its tank T1 via its by-pass valve (BVH), but its discharge valve
(HV) is still fully shut.

d) Switch ON only one CW pump, say PC1 whose suction is from tank T2. Its by-pass
valve BVC1 is still fully opened.
Do not operate PC2. Shut CV2 fully.
Note the CW recirculation from PC1 back into tank T2 via mainly its by-pass valve
BVC1 and also the Heat Exchanger return solenoid valve TSV3A.

e) Practise manipulating the by-pass valve (BVC1) to set various flowrates of CW into the
Heat Exchanger from PC1 as follows:
The manual discharge valve CV1 should remain fully opened.
With BVC1 fully opened, note the CW flowrate {FC at FI(C*)}, pressure
(PG-C) and Shell-side pressure drop (at DPI*). To read DP (Shell), select the
signal to DPI* using the DP Selector Switch provided at the panel, to the DP
(Shell) position and wait till the reading at DPI* is almost steady.

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Manually adjust BVC1 until FC at FI(C*) reads almost 10 USGPM. Note also
DP(Shell) and PG-C.
Shut fully the by-pass valve (BVC1) and note the increase in FC, PG-C and DP
(Shell). Note the CW temperatures at the Heat Exchanger inlet (T1 at TI3*) and
outlet (T2 at TI4*).
Note the Heat Exchanger pressure drop increases with flowrates.

f) Switch ON pump PC2 whose suction is from tank T2. Open fully its manual discharge
valve CV2 and by-pass valve (BVC2). Note the CW flowrate {FC at FI(C*)}, pressure
(PG-C) and Shell-side pressure drop (at DPI*).
Gradually shut only BCV2 until the CW flowrate FC is about 20 USGPM.
Note FC, PG-C and DP(Shell) which increase with the flowrate FC.

g) Open fully BVC2 but shut fully CV2 so that pump PC2 now operates only as a back-
mixing pump for tank T2. Note the drop in FC, PG-C and DP (Shell).
Only pump PC1 is now pumping through the Heat Exchanger. Shut BVC1 fully for
maximum flow from PC1 through the Heat Exchanger.

Switch OFF both the CW pumps PC2 and PC1.

Switch the DP Selector Switch to the equalising (vertical or 0) position.

iv. HW System : Heat Exchanger Tube side.

a) Note TIC5 to check if the water temperature in tank T1 is about 70 C (158oF),

before proceeding to the next procedure (b). Note that the discharge valve (HV) of
the HW pump PH is still shut but its by-pass valve (BVH) is fully opened.
b) Gradually shut the by-pass valve (BVH) fully and simultaneously open its discharge
valve (HV) fully so that the maximum HW flows into the Heat Exchanger and
return into tank T1. Read the HW flowrate {FH at FI(H)*}, pressure (PG-H) and
Tube-side pressure drop (at DPI*). To read DP (Tube), select the DP signal to
DPI* using the DP Selector Switch provided at the panel, to the DP (Tube)
position. Wait till the DP(Tube) reading at DPI* is almost steady to take the
reading.

The temperature of HW in tank T1 will drop due to heat being transferred to the
'metal' body of the Heat Exchanger, even if there is no CW flow in the Heat
Exchanger. Note the HW temperatures at the Heat Exchanger inlet (t1 at TI1*) and
outlet (t2 at TI2*).
WHENEVER THE ANNUNCIATOR TAH3 IS ACTIVATED, PRESS THE
RED ACKNOWLEDGE BUTTON TO SILENCE THE BUZZER.

c) Stop the HW pump PH and note the drop in FH, PG-H and DP (Tube).
Switch the DP Selector Switch to the equalising (vertical or 0) position.
Note that heat from HW is now 'stored' in the Heat Exchanger tubes.
Switch OFF the heaters.

d) Proceed to (C1) PLANNING THE EXPERIMENTS.

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(C1) PLANNING THE EXPERIMENTS

Refer to TABLE 1 and plan out the experiment strategy as follows :-
i. RUN I
a) Run I is done at the following recommended nominal flowrates.
It is NOT necessary to operate at exactly the recommended nominal
flowrates below. A deviation of 5% is acceptable for testing purposes.
CW, FC : 10 USGPM HW, FH : 25 USGPM

b) Please refer to TABLE 1. Three (3) Sets of readings are taken for every RUN.
Each Set of temperature readings consists of four readings to be taken
simultaneously: CW
temperatures - inlet T1 at TI3* and outlet T2 at TI4*,
HW temperatures inlet t1 at TI1* and outlet t2 at TI2*.
Each set of flowrate readings consists of two readings:
CW flowrate (FC at FI(C)*),
HW flowrate (FH at FI(H)*).

Each set of pressure drop readings consists of two readings:

DP (Shell) at DPI*, with the DP Selector Switch at the DP (Shell) position.
DP (Tube) at DPI*, with the DP Selector Switch at the DP (Tube) position.

Each set of Heat Exchanger inlet gauge pressure readings consists of two
readings:
PG-C of CW at the CW pipeline, inlet to the Shell side of the Heat Exchanger.
PG-H of HW at the HW pipeline, inlet to the Tube side of the Heat Exchanger.
c) Note that the HW temperature in tank T1 drops (note TIC5) when the heater
input is inadequate to meet with the heat (QC) removed by CW. Hence the
second and third Sets of temperature readings may be taken at decreasing heat
load, but the water temperature at tank T1 must be at least 60 C.

d) Concentrate on taking the three (3) Sets of temperature, flowrate and pressure
drop readings. The pressure drop readings DP (Shell) and DP (Tube) are taken at
the panel-mount DPI*, using the DP signal Selector Switch provided. Note that
the pressure drop depends on the flowrate and not on the temperature.

e) Repeat the above procedure for other RUNS (II, III, etc) at the following CW
and HW recommended nominal flowrates. It is NOT necessary to operate at
exactly the recommended nominal flowrates. A deviation of 5% is acceptable.
Below is a summary list of the recommended nominal flowrates.
RUN CW, FC HW, FH
I 10 USGPM 25 USGPM
II 10 USGPM 20 USGPM
III 10 USGPM 15 USGPM
IV 10 USGPM 10 USGPM
V 6 USGPM 10 USGPM

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(C2) EXPERIMENTAL PROCEDURES

WHENEVER THE ANNUNCIATOR TAH3 IS ACTIVATED DURING THE
COURSE OF THE EXPERIMENT, PRESS THE RED ACKNOWLEDGE BUTTON
TO SILENCE THE BUZZER.

With a good overview of the experiment plan detailed in C1, proceed with RUN 1 as
follows :-
i) Check that all the pump suction valves (for PH, PC1, PC2) are fully opened all
the time.
Open BVC2 fully but shut CV2 fully so that PC2 shall operate as a back-mixing
pump for tank T2 in the next experiment.
Open fully both CV1 and BVC1. Only PC1 shall be used here to pump CW into the
Heat Exchanger in the next experiment.
Do not switch on any CW pumps (PC1, PC2) yet.
Shut HV fully but open BVH fully.
Start pump PH for HW to circulate around tank T1 via only BVH.
Start the heaters and note TIC5.
When the HW in tank T1 is almost 70oC/158oF (see TIC5), open HV fully.
Quickly adjust the HW flowrate to about 25 USGPM by regulating its by-pass
valve BVH.
Switch ON both the CW pumps PC1 and PC2.
Quickly adjust the CW flowrate to about 10 USGPM by regulating the by-pass valve
BVC1.
Switch the DP Selector Switch to the DP(Shell) position.

ii ) a) Take the first Set of temperature and flowrate readings:

CW: Temperature - inlet/outlet, TI3* (T1), TI4* (T2):
Flowrate FC at FI(C*)
HW: Temperature - inlet/outlet, TI1* (t1), TI2* (t2) :
Flowrate FH at FI(H*)

Note that the CW inlet temperature (T1) is increasing gradually. The CW outlet
temperature (T2) varies together with the HW inlet/outlet temperatures t1/t2. It
is important that all the temperature and flowrate readings be taken almost
simultaneously.
Record these readings appropriately in TABLE 1.
Also record the respective inlet pressure and pressure drop of the CW and HW
flow streams. For the pressure drop readings, DP (Shell), DP (Tube) at the
panel-mount DPI*, use the DP signal Selector Switch appropriately as
explained below.
CW : PG-C; DPI * for DP (Shell) with the DP Selector Switch at the DP
(Shell) position.

HW: PG-H; DPI* for DP (Tube) with the DP Selector Switch at the DP
(Tube) position.

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To take the DP readings at DPI*, wait till they are fairly steady.
Then take the DP reading at its highest reading (i.e. peak reading) just when it
starts to decrease.

b) Continue and take the second and third Sets of the above readings for RUN I
consecutively. The last Set of temperature readings should be taken when all the
temperatures are fairly steady.

iii.

Check that the HW pump PH is running with BVH fully opened but HV
fully shut.
With the heaters ON, heat till the HW in tank T1 is almost 70C/158F
(see TIC5).
Open HV fully.
Adjust the HW flowrate until FH at FI (H*) is almost at the
recommended nominal flowrate for the RUN.

Exp/HE 10

RUN
StopIall
is the
completed,
CW pumps PC1
with andsets
three PC2 of. the above readings.
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This is done by regulating the by-pass valve BVH with HV fully opened.
(However, if the flowrate is still too high even when its by-pass valve is
fully open, gradually shut its discharge valve, HV, to get the required HW
flowrate).
Start the CW pumps PC1, PC2 with CV1/BVC1/BVC2 fully opened but
CV2 fully shut. Note FC at FI(C*).
Adjust FC to the recommended nominal flowrates for the RUN by
regulating the by-pass valve BVC1 with CV1 fully opened.
(However, if the CW flowrate (FC) from PC1 is still inadequate even when
its by-pass valve BVC1 is fully shut, use the second CW pump (PC2) by
gradually opening CV2 and simultaneously shutting BVC2 to get the
required CW flowrate).
Switch the DP Selector Switch to the DP(Shell) position.
Take the various readings for the RUN. Refer to TABLE 1 of the
appropriate RUN.

To end a RUN after getting 3 sets of readings

- Stop all the CW pumps PC1, PC2.
- Switch the DP Selector Switch to the equalising (vertical or
0) position.
- With the HW pump PH and the heaters still ON, shut fully HV but
open BVH fully.

(C3) PLANT SHUT-DOWN PROCEDURE

When all the experimental RUNS are completed, shut down the Plant as follows:
i) Switch OFF the heaters.
ii) Check that all the pumps (PH, PC1, PC2) are switched OFF.
iii) Switch the DP Selector Switch to the equalising (vertical or 0) position.
iv) Switch OFF the main power supply to the Plant at the front of the panel/ cubical.
Open all the pumps suction valves, discharge valves (HV, CV1, CV2) and by-pass
v) valves (BVH, BVC1, BVC2).

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(D) EXPERIMENTAL RESULTS

To calculate QC and QH, please refer to section (E) CALCULATION.

TABLE 1

RUN I Set 1 Set 2 Set 3

CW HW CW HW CW HW

Nominal Flow, USGPM FC: 10 FH: 25 10 25 10 25

Actual Flow, USGPM FC: ____ FH: ____

Temp, C/F, Inlet TI3: T1: ____ TI1: t1: ____

Temp, C/F Outlet TI4: T2: ____ TI2: t2: ____

Pressure, psig, Inlet PG-C: ______ PG-H: ______

Pressure Drop, mm H2O DP : ______ DP : ______

(Shell) (Tube)

CALCULATE FOLLOWING:
Temp Change, C/F T2 - T1: ____ t1 - t2 : ____

Average Temp, C/F T2 + T1 : ___ t1 + t2 : ____

2 2

Q, Head Load, BTU/HR QC: ____ QH: ____

Compute ratio QC QC : QC : QC :
QH QH QH QH

SELECT Set 1 or Set 2 or Set 1 is Set 2 is Set 3 is

Set 3, based on the best Selected/Not selected Selected/Not Selected/Not
convergence of QC and QH selected selected
i.e. QC is nearest to 1.0
QH
For Selected Set, compute
0.5 (QC + QH), BTU/HR

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TABLE 1 (cont.)

RUN II Set 1 Set 2 Set 3

CW HW CW HW CW HW

Nominal Flow, USGPM FC: 10 FH: 20 10 20 10 20

Actual Flow, USGPM FC: ____ FH: ____

Temp, C/F, Inlet TI3: T1: ____ TI1: t1: ____

Temp, C/F Outlet TI4: T2: ____ TI2: t2: ____

Pressure, psig, Inlet PG-C: ______ PG-H: ______

Pressure Drop, mm H2O DP : ______ DP : ______

(Shell) (Tube)

CALCULATE FOLLOWING:
Temp Change, C/F T2 - T1: ____ t1 - t2 : ____

Average Temp, C/F T2 + T1 : ___ t1 + t2 : ____

2 2

Q, Head Load, BTU/HR QC: ____ QH: ____

Compute ratio QC QC : QC : QC :
QH QH QH QH
SELECT Set 1 or Set 2 or Set 1 is Set 2 is Set 3 is
Set 3, based on the best Selected/Not selected Selected/Not Selected/Not
convergence of QC and QH selected selected
i.e. QC is nearest to 1.0
QH
For Selected Set, compute
0.5 (QC + QH), BTU/HR

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TABLE 1 (cont.)

RUN III Set 1 Set 2 Set 3

CW HW CW HW CW HW

Nominal Flow, USGPM FC: 10 FH: 15 10 15 10 15

Actual flow, USGPM FC: ____ FH: ____

Temp, C/F, Inlet TI3: T1: ____ TI1: t1: ____

Temp, C/F, Outlet TI4: T2: ____ TI2: t2: ____

Pressure, psig, Inlet PG-C: ______ PG-H: ______

Pressure Drop, mm H2O DP : ______ DP : ______

(Shell) (Tube)

CALCULATE FOLLOWING:
Temp Change, C/F T2 - T1: ____ t1 - t2 : ____

Average Temp, C/F T2 + T1 : ___ t1 + t2 : ____

2 2

Q, Head Load, BTU/HR QC: ____ QH: ____

Compute ratio QC QC : QC : QC :
QH QH QH QH

SELECT Set 1 or Set 2 or Set 1 is Set 2 is Set 3 is

Set 3, based on the best Selected/Not selected Selected/Not Selected/Not
convergence of QC and QH selected selected
i.e. QC is nearest to 1.0
QH
For Selected Set, compute
0.5 (QC + QH), BTU/HR

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TABLE 1 (cont.)

RUN IV Set 1 Set 2 Set 3

CW HW CW HW CW HW

Nominal Flow, USGPM FC: 10 FH: 10 10 10 10 10

Actual Flow, USGPM FC: ____ FH: ____

Temp, C/F, Inlet TI3: T1: ____ TI1: t1: ____

Temp, C/F, Outlet TI4: T2: ____ TI2: t2: ____

Pressure, psig, Inlet PG-C: ______ PG-H: ______

Pressure Drop, mm H2O DP : ______ DP : ______

(Shell) (Tube)

CALCULATE FOLLOWING:
Temp Change, C/F T2 - T1: ____ t1 - t2 : ____

Average Temp, C/F T2 + T1 : ___ t1 + t2 : ____

2 2

Q, Head Load, BTU/HR QC: ____ QH: ____

Compute ratio QC QC : QC : QC :
QH QH QH QH
SELECT Set 1 or Set 2 or Set 1 is Set 2 is Set 3 is
Set 3, based on the best Selected/Not selected Selected/Not Selected/Not
convergence of QC and QH selected selected
i.e. QC is nearest to 1.0
QH
For Selected Set, compute
0.5 (QC + QH), BTU/HR

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TABLE 1 (cont.)

RUN V Set 1 Set 2 Set 3

CW HW CW HW CW HW

Nominal Flow, USGPM FC: 6 FH: 10 6 10 6 10

Actual Flow, USGPM FC: ____ FH: ____

Temp, C/F, , Inlet TI3: T1: ____ TI1: t1: ____

Temp, C/F, Outlet TI4: T2: ____ TI2: t2: ____

Pressure, psig, Inlet PG-C: ______ PG-H: ______

Pressure Drop, mm H2O DP : ______ DP : ______

(Shell) (Tube)

CALCULATE FOLLOWING:
Temp Change, C/F T2 - T1: ____ t1 - t2 : ____

Average Temp, C/F T2 + T1 : ___ t1 + t2 : ____

2 2

Q, Head Load, BTU/HR QC: ____ QH: ____

Compute ratio QC QC : QC : QC :
QH QH QH QH
SELECT Set 1 or Set 2 or Set 1 is Set 2 is Set 3 is
Set 3, based on the best Selected/Not selected Selected/Not Selected/Not
convergence of QC and QH selected selected
i.e. QC is nearest to 1.0
QH
For Selected Set, compute
0.5 (QC + QH), BTU/HR

Exp/HE 16
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(E) CALCULATION
American Engineering Units are used here since KERN and other technical datas in the
APPENDIX are in such units.

PART I
i. Heat Load and Heat Balance
This part of the calculation is to use the datas in TABLE I to check the heat load QH and QC
( BTU ) and to select the set of values where QC is closest to QH.
hr

For HW: QH BTU = FH (lbm) x specific heat (BTU) x (t1 - t2) oF.
hr hr lbmoF

For CW: QC BTU = FC (lbm) x specific heat (BTU) x (T2 - T1) oF.
hr hr lbmoF

For each run, compare the calculated values of QH and QC and select the Set of
temperature and flowrate datas where the calculated values of QH and QC are closest
to each other. This selected Set of datas shall be used to represent the results of the
particular RUN, and be used for the following subsequent calculation.

ii. LMTD
LMTD = (t1 - T2) - (t2 - T1) , oF
ln (t1 - T2)/(t2 - T1)

R = - (T1 - T2) S = - (t2 - t1)

- (t2 - t1) - (T1 - t1)

The correction factor FT for 1 Shell Pass and 2 or more Tube Passes is given in *KERN
FIG18, a zeroxed copy of which is enclosed in the Appendix section.

Thus the corrected LMTD = FT x LMTD calculated above, oF.

*Kern : Process Heat Transfer

iii. Overall Heat Transfer Coefficient U

The total heat transfer area of the HEAT EXCHANGER, A = 31.50 ft2

\U BTU = Q (BTU) x 1 x 1
2 o
hr.ft . F hr A ft2 LMTD x FT, oF

Theoretically Q above is equals to QH or QC.

Otherwise there is an error in QH or QC, most probably due to errors in the temperatures and
flowrates. Calculate U based on the average of the selected Set of QC and QH values for each
RUN i.e. take Q = 0.5 (QC + QH), to get an average value of U.

Exp/HE 17
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The results of the calculation are tabulated as shown in TABLE 2 below.

TABLE 2 : Calculation of Head Load, LMTD and U from PART I.

RUN QC QH 0.5(QC + LMTD x FT U

QH)

BTU BTU BTU oF BTU

HR HR HR hr. ft F

I.

II.

III.

IV.

V.

The U value calculated above shall be referred to as the 'dirty' overall heat transfer coefficient UD.

Exp/HE 18
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PART II : REYNOLDS NUMBER

For this part of the Calculation, the students are to calculate the Reynolds numbers at the Shell
and at the Tube sides i.e. Re(s), Re(t).
The selected or representative Set of flowrates and temperatures obtained from each of the RUNS,
from RUN I to RUN V are to be used.
The Reynolds number calculated are to be tabulated in TABLE 3.

Shell-side Re(s) for CW

Re(s) = De. Gs
m

where de = 4 ( 1/2 PT x 0.86 PT - 1/2 p do2 ) ins. Refer Kern equation 7.5.
4
-------------------------------------
1/2 p do

PT = Pitch = 0.81 ins

De = de ft
12
do = Tube outside diameter, ins.

m = Viscosity, taken at the average fluid temperature in the Shell, lbm

ft. hr.
Gs = Ws lbm
As hr. ft2

Ws = Flowrate in lbm
hr

As = Shell ID x Clearance x Baffle space

PT x 144

= 6.065" x 0.19" x 3"

0.81" x 144

= 0.029 ft2

Exp/HE 19
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Tube-side Re(t) for HW

Re(t) = D. Gt
m

where D = Tube ID = 0.04125 ft

m = Viscosity, taken at the average fluid temperature in the tube, lbm

ft. hr
Gt = Wt lbm
At hr. ft2

Wt = Flow rate in lbm

hr

At = Nos of tubes x flow area per tube

Nos of tube passes

= 32 x 0.1924 ft2
2 144

= 0.02139 ft2

* It should also be shown here, at which HW flowrate is Re(t) less than 3000.
Try the calculation with HW at 3.5 USGPM.

Refer to FIG26 enclosed and note the sharp rise in friction factor for laminar flow.

Refer to FIG24 enclosed and note the sharp drop in heat transfer for laminar flow.

Exp/HE 20
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PART III : HEAT TRANSFER COEFFICIENT

For this part of the Calculation, the student are to calculate the 'clean' overall heat transfer
coefficient UC from the individual heat transfer coefficient ho and hi for inside and outside fluids.
The calculated results are to be tabulated in TABLE 3.

The Dirt factor Rd which is UC - UD is to be compared against say

UC x U D

0.003 hr. ft2 oF for water/water heating or cooling heat transfer.

Btu

ho : BTU
hr. ft2 oF
--------------------------

Please refer to Kern Fig 28, a zeroxed copy of which is enclosed in the Appendix section, to
calculate ho, at the various Reynolds number calculated in PART II.

jH = ho. De ( Cp. m ) -1/3 [( m )] -0.14

k (k) -1/3 [(mw)] -0.14

hi : BTU
hr. ft2 oF
--------------------------

Please refer to Kern Fig 24, a zerozed copy of which is enclosed in the Appendix section, to
calculate hi and hio, at the various Reynolds number calculated in PART II.

jH = hi. D ( Cp. m ) -1/3 [( m )] -0.14

k (k) -1/3 [(mw)] -0.14

hio = hi x ID
OD

Exp/HE 21
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Rd : hr. ft2. oF
BTU
---------------------------

UC = hio x ho
hio + ho

UD is established from PART I of the Calculation and tabulated in TABLE 2.

Rd = UC - UD
UC . U D

Is Rd more than 0.003 hr. ft2. oF ?

BTU

Note that UC is calculated from the Heat Exchanger heat transfer coefficients (ho, hi, hio), the
Reynolds numbers (i.e. flowrates), the flowing fluids properties and the Heat Exchanger diameters.
UD however is determined from actual heat transfer experiments at the Heat Exchanger. It is the
dirty or design heat transfer coefficient. Fouling reduces UD . Fouling may get worse with
operation, resulting in reduced heat transfer and increasing pressure drop (and loss of flow).

Exp/HE 22
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PART IV : PRESSURE DROP

PART IV of the exercise is to determine the following:-
HW : The Measured Tube-side pressure drop DP (Tube) which will be corrected and
is expected to be more than the Calculated Tube-side pressure drop.
CW : The Measured Shell-side pressure drop DP (Shell) which will be corrected and
is expected to be more than the Calculated Shell-side pressure drop.

The students are to calculate the pressure drop at the Shell-side and at the Tube-side i.e. DP(Shell),
DP(Tube). The calculated results are to be tabulated in TABLE 3.
The Calculated DP(Shell) and DP(Tube) are to be compared to the Measured DP(Shell) and
DP(Tube). Correction to the Measured DP(Shell) and DP(Tube) can be made.

Pressure Drop, Shell Side

Refer Kern equation 7.44 or Kern Fig 29.
Kern Fig 29 is enclosed in the Appendix section.

Pressure Drop Tube Side

Refer to Kern equation 7.45/7.46 or Kern Fig 26/27. Kern Fig 26/27 is enclosed in the
Appendix section.

The total pressure drop must include the tube side return (U-bend) pressure loss.

Pressure Drop Measurement

The Shell-side and Tube-side pressure drop (DP) are measured using the Differential Pressure
Transmitter (DPT) and then indicated digitally at the panel DP Indicator (DPI*). A Selector
Switch with a set of 5 solenoid valves allows both the Shell and Tube-sides pressure drop i.e. DP
(Shell), DP (Tube), to be measured one at a time. Please take note of the following :-
a) The differential pressure (DP) tapping points to measure the respective pressure drop
must be at the same elevation. Otherwise, the static head must be corrected.

b) To avoid excessive turbulence and vortices at the vicinity of the differential pressure (DP)
tapping points, the tapping points should be located with adequate upstream/downstream
straight pipe runs away from turbulence and vortices. The pressure drop readings will be
noisy otherwise, especially if the flow stream has just negotiated from a change in flow area
or direction or if it is too near the pump discharge.

c) Note the location of each pair of tapping points. The DP measured by DPT (and displayed at
DPI*) is the DP of the Heat Exchanger (Shell/Tube) PLUS various pipe elbows and tees
and pipe length. These additional DP can be much more than DP(Tube) or DP(Shell) and
must be corrected (subtracted) from the Measured DP(Tube) and DP(Shell). Please refer to
the Appendix section CORRECTION TO THE MEASURED DP(TUBE) AND
DP(SHELL).

d) When there is no flow to the Heat Exchanger, the DP Selector Switch should be switched to
the equalising (vertical or 0) position. The DPI* will display almost 0 mmWG 0.5% i.e.
25 to 25 mm H2O.

Exp/HE 23
 CHE504

Exp/HE
TABLE 3

RUN ACTUAL PART II: PART III: Heat Transfer Coefficient PART IV: Pressure Drop
FLOW Reynolds Number

USGPM BTU Hr.ft2. F SHELL SIDE TUBE SIDE

Hr.ft2. F BTU mm H2O or psi mm H2O or psi

Measured Measured
FC: Re (s) Re (t) ho hio Uc UD Rd Calculated Measured and Calculated Measured and
FH: Corrected Corrected

FC:
I. FH:

FC:
II. FH:

23
FC:
III. FH:

FC:
IV. FH:

FC:
V. FH:

NOTE:
Pressure conversion : 1 psi is 2.3088 ft H2O or 703.7 mm H2O, at 60F
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APPENDIX SECTION

SOME USEFUL (APPROXIMATE) DATAS FOR WATER

TEMP

71.1 61.00 8.156 2.6947 x 10-4 0.3840

65 0.985 61.30 8.182 2.9272 x 10-4 1.00 0.3830
60 61.38 8.207 3.1503 x 10-4 0.3790
54.5 0.9872 8.227 3.430 x 10-4
48.9 0.9901 61.71 8.253 3.7565 x 10-4 0.3710
48 3.8223 x 10-4
40 61.94 8.289 4.4083 x 10-4
35 0.995 62.06 8.296 4.8572 x 10-4 0.999 0.3605

OTHER USEFUL DATAS

Assume 1 m3/Hr is 4.4 USGPM
Assume 1 psi is 2.3088 ft water or 27.72 ins or 703.72 mm Water at 60F(SG = 1.0)

CORRECTION TO THE MEASURED DP(TUBE) AND DP(SHELL)

The following are the calculated piping pressure drop that must be subtracted from the Measured
DP(Tube) and DP(Shell), to get the actual DP(Tube) and DP(Shell) of the Heat Exchanger. Note
that pressure drop increases with flowrates.
FLOWRATES CALCULATED PIPING CALCULATED PIPING
PRESURE DROP FOR HW PRESURE DROP FOR CW
25 USGPM/5.68 m/Hr 2713 mm H2O 1805 mm H2O
20 USGPM/4.55 m/Hr 1772 mm H2O 1198 mm H2O
15 USGPM/3.41 m/Hr 1050 mm H2O 710 mm H2O
10 USGPM/2.27 m/Hr 521 mm H2O 342 mm H2O
6 USGPM/1.36 m/Hr - 137 mm H2O

Remarks : Calculated Piping Pressure Drop for HW.

Consider the two (2) tapping points to measure DP(Tube) at the HW flowstream. Between these
tapping points and the Heat Exchanger inlet/outlet ports, there are
i) 4.5 ft of 1 pipe between the HW tapping points and the Heat Exchanger inlet/outlet ports.
ii) two (2) elbows which are equivalent to 2.7 ft x 2 or 5.4 ft of 1 pipe.
iii) two (2) tees used as L which are equivalent to 5.6 ft x 2 or 11.2 ft of 1 pipe.
The above HW piping pressure drop due to 21.1 ft of 1 pipe is also measured together as part of
the Measured DP(Tube).
The pressure drop due to 21.1 ft of 1 pipeline at various HW flowrates can be calculated and are
tabulated in the above table.

Remarks : Calculated Piping Pressure Drop for CW.

Similarly for the CW flowstream, there are
i) 3 ft of 1 pipe between the CW tapping points and the Heat Exchanger inlet/outlet ports.
ii) two (2) tees used as L which are equivalent to 5.6 ft x 2 or 11.2 ft of 1 pipe.
The above CW piping pressure drop due to 14.2 ft of 1 pipeline can be calculated at various CW
flowrates, as tabulated in the above Table.

Exp/HE 25

THERMAL
CONDUCTIVITY
SG
F/ft DENSITY DENSITY
F VISCOSITY HEAT