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DESIGN AND OPERATION OF DOUBLE PIPE HEAT EXCHANGER

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TLEP International Journal Of Chemical Engineering Research
ISSN 2488-9324(Paper) E-ISSN 2488-9334(Online)
Vol. 3. 2017

Design and Operation of Double Pipe

Heat Exchanger
IDONGESIT EFFIONG SAMPSON
Department of Chemical Engineering, Rivers State University of Science and Technology, Port
Harcourt, Nigeria.
E-mail: [email protected]

ABSTRACT
The double pipe heat exchanger is one heat exchanger pipe inside another larger pipe for either counter flow or
parallel flow pattern. The heat exchange duty allows calculation of the log mean temperature difference and that
together with the estimated overall heat transfer coefficient allows calculation of the required heat transfer surface
area. Then pipe sizes, pipe lengths and number of bends can be determined. The double heat exchanger can be
operated counter flow or parallel flow. The counter current mode enhances more area for heat transfer. Operations
are enhanced by auxiliary equipments such as valves, pumps, meters, switches and controllers. Operations are
carried out in accordance with operational procedures taking into consideration safety regulations.

Keywords: Double Pipe Heat Exchanger, Log Mean Temperature Difference, Overall Heat Transfer Coefficient.

1.0. INTRODUCTION
Temperature is the average kinetic energy in the molecules of a substance. Heat exchangers are used to transfer that
energy from one substance to another. In process plants it is necessary to control the temperature of incoming and
outgoing process streams. These streams can either be gases or liquids. Heat exchangers raise or lower the
temperature of these streams by transferring heat to or from the stream.

Heat exchangers are devices that exchange the heat between two fluids of different temperatures that are separated
by a solid wall. The temperature gradient or differences in temperature is the driving force for heat transfer.

Transfer of heat occurs in three modes: Radiation, Conduction and Convection.

In the use of heat exchangers, radiation does not take place. However, in comparison to conduction and convection,
radiation does not play a major role.

Conduction occurs as the heat from the higher temperature fluid passes through the solid pipe wall. To maximize the
heat transfer the wall should be thin and made of a very conductive material. The biggest contribution to heat
transfer in a heat exchanger is made through convection.

In heat exchanger, forced convection allows for the transfer of heat of one moving stream to another moving stream.
With convection, as heat is transferred through the pipe wall it is mixed into the stream and the flow of the stream
removes the transferred heat. This maintains a temperature gradient between the two fluids.

The double pipe heat exchanger is one of the simplest types of heat exchangers. It is called double pipe heat
exchanger because one fluid flows inside a pipe and the other fluid flows between that pipe and another pipe that
surrounds the first. This is concentric tube construction.

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Flow in a double-pipe heat exchanger can be co-current or countercurrent. There are two flow configurations: co-
current is when the flow of the two streams is in the same direction. Countercurrent is when the flow of the streams
is in opposite directions.

As conditions in the pipes change: inlet temperatures, flow rates, fluid properties, fluid composition etc; the amount
of heat transferred also changes.This transient behavior leads to change in process temperatures, which will lead to a
point where the temperature distribution becomes steady.

When heat is beginning to be transferred, this changes the temperature of the fluids. Until these temperatures reach a
steady state, their behaviour is dependent on time.In the double pipe heat exchanger, a hot process fluid flowing
through the inner pipe transfers its heat to the cooler fluid flowing in the outer pipe. The system is in steady state
until conditions change such as flowrate or inlet temperature.

These changes in conditions cause the temperature distribution to change with time until a new steady state is
reached. The new steady state will be observed once the inlet and outlet temperatures for the process and coolant
fluid becomes stable.

In reality, the temperatures will never be completely stable, but with large enough changes in inlet temperatures or
flowrates a relative steady state can be experimentally observed.The theory behind the operation of a double-pipe
heat exchanger is covered in Incropera & Dewitt (1996). Also in this same textbook is the derivation of how
transient behavior is treated with respect to heat transfer. As with any process the analysis of a heat exchanger
begins with an energy and material balance. Before doing a complete energy balance a few assumptions can be
made. The first assumption is that the energy lost to the surroundings from the cooling water or from the Ubends in
the inner pipe to the surroundings is negligible. We also assume negligible potential or kinetic energy changes and
constant physical properties such as specific heats and density. These assumptions also simplify the basic heat-
exchanger equations.

The determination of the overall heat-transfer coefficient is necessary in order to determine the heat transferred from
the inner pipe to the outer pipe. This coefficient takes into account all of the conductive and convective resistances
(k and h, respectively) between fluids separated by the inner pipe, and also takes into account thermal resistances
caused by fouling (rust, scaling, i.e.) on both sides of the inner pipe. For a double-pipe heat exchanger the overall
heat transfer coefficient, U, can be expressed as in equation (5).

In a heat exchanger the log-mean temperature difference is the appropriate average temperature difference to use in
heat transfer calculations. The equation for the log-mean temperature difference can be expressed as in equations (3)
and (4).

Fluid properties such as density, viscosity and heat capacity are evaluated at the average temperatures. The average
is found by using the inlet and outlet values as in equations (1) and (2)

Thermal conductivity, k, can be evaluated at the average of the average temperatures. In a double-pipe heat
exchanger the inner pipe is made of a conductive metal and is thin. The problem can be further simplified if the
equipment is assumed to be clean, which means that no scaling exists. This is a poor simplification with the double-
pipe heat exchanger in the laboratory, because it is many years old. The fouling factors Rfo and Rfi can be looked up
from various sources, including Standards of the Tubular Exchange Manufacturers Association (1978) or lumped
together and determined experimentally.

The only part of the overall heat-transfer coefficient that needs to be determined is the convective heat-transfer
coefficients. Correlations are used to relate the Reynolds number to the heat-transfer coefficient. The Reynolds
number, a dimensionless ratio of the inertial and viscous forces in flow is given as in equation (7).

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Vol. 3. 2017

In the inner pipe, if the Reynolds is less than 2000 this is considered to be laminar flow and the Nusselt number is
equal to 4.36. If the Reynolds number is greater than 10,000, the Nusselt number is given by equation (10) and the
Prantyl number by equation (11).

This gives a Nusselt number that can then be used to find hi as in equation (9).

The convective heat transfer coefficient in the annulus is more difficult to determine. The hydraulic diameter is used
to find the Reynolds number. The hydraulic diameter is defined as the cross-sectional area perpendicular to flow
divided by the wetted perimeter. With the Reynolds number calculated the same correlations apply and with these
ho can be determined. Once all the separate heat-transfer coefficients are calculated an overall heat transfer
coefficient is calculated. Now everything that was necessary for an energy balance is available. With the previous
assumptions made earlier the dynamic equations would be as in equations (13) and (14).

With the transient data taken experimentally an overall heat-transfer coefficient can be determined at each time step.
This can be solved numerically.

1.1. Modes of Operation

Co-Currrent: The flow of the two streams is in the same direction.

Counter-Current: The flow of the two streams is in opposite directions.

Countercurrent flow gives the highest heat transfer coefficient.

Fluid 2 cold
Tout

Fluid 1 out
Tin hot Tout
Fluid 1 in

Tin cold
Fig. 1: Double pipecoldfluid2
heat exchanger counter flow.
fluid

Fluid 2 in
Tin

Fluid 1 out
Tin Tout
Fluid 1 out

Tout
Fluid 2 out parallel flow.
Fig. 2: Double pipe heat exchanger

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TLEP International Journal Of Chemical Engineering Research
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For counter flow, 𝑇2 out can approach 𝑇1 in, which is higher than 𝑇2 out. For Parallel flow,𝑇2 out can only approach
𝑇1 out, but cannot be greater.

Fig. 3: Process flow diagram for the double-pipe heat exchanger

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Fig. 4: Pictorial view of Double pipe heat exchanger

Green & Perry (1997) state that due to the need for removable bundle construction and the ability
to handle differential thermal expansion while avoiding the use of expansion joints, the U shaped
configuration shown in the figure above has become the standard in the industry.

The hairpin heat exchanger, unlike the removable bundle style is designed for bundle insertion
and removal from the return and other, than the tube sheet end. This is accomplished by means of

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TLEP International Journal Of Chemical Engineering Research
ISSN 2488-9324(Paper) E-ISSN 2488-9334(Online)
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removable split rings which slide into grooves machined around the outside of each tube sheet and lock the tube
sheets to the external closure flanges. This provides a distinct advantage in maintenance since bundle removal takes
place at the exchanger end furthest from the plant process piping without disturbing any gasketed joints of this
piping.

Green & Perry (1997) gives one benefit of the hairpin exchanger as its ability to handle high tube side pressures at a
lower cost than other removable bundle exchangers.

This is due in part to the lack of pass partitions at the tubesheets which complicate the gasketing design technology,
has allowed the building of dependable removable bundle, hairpin multitubes at tubeside pressures of 825 bar
(12,000 psi).

1.2. Temperature Driving Force:

1.2.1. Mean Temperature Difference

Before determining the heat transfer area required for a given duty, an estimate of the mean temperature difference
∆𝑇𝑙𝑚 must be made. This is normally calculated from the difference in fluid temperatures at the inlet and outlet of
the exchanger. Williams et al. (2002) states that:

𝑇1,a = [𝑇1 ,0 + 𝑇1 , 𝑖]/2 (1)

𝑇𝑜,𝑎 = [𝑇𝑜,𝑜 + 𝑇𝑜 ,𝑗 ]/2 (2)

Fluid properties such as density, viscosity, heat capacity are evaluated at average temperatures, while thermal
conductivity k can be evaluated at the average of the average temperatures.

1.2.2. Logarithmic Mean Temperature Difference

When heat capacities of both streams are constant and there is no phase change at constant pressure for streams that
contain a single component: For countercurrent flow, the logarithmic mean temperature difference is given in
Coulson et al. (2009) as:

𝑇1 −𝑡 2 − 𝑇2 −𝑡 1
∆𝑇𝑙𝑚 = 𝑇 1 −𝑡 2 (3)
ln
𝑇 2 −𝑡 1
In heat exchanger, ∆𝑇𝑙𝑚 is the appropriate average temperature difference to use in heat transfer calculations.

For Co-current flow:

𝑇1 −𝑡 1 − 𝑇2 −𝑡 2
∆𝑇𝑙𝑚 = 𝑇 1 −𝑡 1 (4)
𝐼𝑛
𝑇 2 −𝑡 2

Logarithmic mean temperature difference can only apply when there is no change in specific heats, the overall heat
transfer coefficient is constant and there are no heat losses. In design, these conditions can be assumed to be satisfied
provided the temperature change in each fluid stream is not large.

1.2.3. Overall Heat Transfer Coefficient

The overall heat transfer coefficient is necessary in order to determine the heat transferred from the inner pipe to the
outer pipe. The coefficient takes into account all of the conductive and convective resistances (k and h

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respectively) between fluids separated by the inner pipe and also takes into account thermal resistances caused by
fouling (rust, scaling, etc) on both sides of the inner pipe.

The overall heat transfer coefficient for a double pipe heat exchanger as given in Williams et al. (2002) is expressed
as below:

1 1 𝑅𝑓𝑜 1 𝑑 𝑖,𝑜 𝑅𝑓 𝑖 1
=𝐴 + + 2.𝑘.𝜋𝑙 𝐼𝑛 + +𝑕 5
𝑈.𝐴 𝑜 𝑕𝑜 𝐴𝑜 𝑑 𝑖,𝑖 𝐴𝑖 𝑜 .𝐴 𝑖

Once all separate heat-transfer coefficients are calculated an overall heat transfer coefficient can be calculated being
the sum of the inverse of the individual heat transfer coefficients.

1.2.4. Quantity of Heat Transferred

After determining the heat exchange duty and calculating the log mean temperature difference. An estimated value
of the overall heat transfer coefficient U enables calculations for the heat transfer surface area A from the equation
given in Bengtson (2010).

𝑄 = 𝑈𝐴 ∆𝑇𝑙𝑚 (6)

1.2.5. The Heat Exchanger Layout

From the surface area, the diameter and lengths of both the inner pipe and outer pipe are determined and the length
of straight section and number of bends. In the double pipe heat exchanger, the inner pipe is made of a conductive
metal and is thin. To prevent the two pipes of the heat exchanger from coming in contact with one another, thin
metal plates called fins are welded to the outside of the smaller pipe. These fins also aid in the transfer of heat from
hotter fluid to the cooler fluid.

1.2.6. Reynolds Number: Is a dimensionless fluid property; It is a ratio of the inertial forces to the viscous
forces in flow. It is given in William et al. (2002) that:

𝑑 𝑖,𝑖 𝑀𝑖
𝑅𝑒𝑖 = (7)
𝜇 𝑖 𝑎𝑖

In the inner pipe, if the Reynolds number is less than 2,100 the flow is considered to be laminar and if greater than
2,100 the flow is considered turbulent.

1.2.7. The Hydraulic Mean Diameter (de):

To find Reynolds number, the hydraulic mean diameter is used. The hydraulic mean diameter is defined as cross
sectional area perpendicular to flow divided by the wetted perimeter. Coulson et al. (2009) gives the formula for
hydraulic mean diameter as:

4 ×𝑐𝑟𝑜𝑠𝑠 −𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎

𝑑𝑒 = (8)
𝑡𝑕𝑒 𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟

𝜋
4 𝑑𝑜 2 ,𝑖 − 𝑑𝑖 2 ,𝑜 4
= = 𝑑𝑜,𝑖 − 𝑑𝑖,𝑜
𝜋 𝑑𝑜,𝑖 + 𝑑𝑖,𝑜

𝑑𝑜,𝑖 − 𝑑𝑖,𝑜 = 𝑑𝑖,𝑖

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That is the inside diameter of outer pipe minus the outside diameter of inner pipe gives the inner diameter of inner
pipe.

1.2.8. Nusselt Number

The Nusselt number can be used to find 𝑕𝑖.

𝑕 𝑖 𝑑 𝑖,𝑖
𝑁𝑢𝑖 = (9)
𝑘𝑖

It is stated in Williams et al. (2002) that for laminar flow, the Nusselt number is equal to 4.36.

If the Reynolds number is above ten thousand, the Nusselt number is given in Williams et al. (2002) as:
4
𝑁𝑢𝑖 = 0.023 𝑅𝑒𝑖 𝑃𝑟𝑖 𝑛 (10)
5

For a fully developed turbulent flow

1
Where: 𝑅𝑒𝑖 ≥ 10,000, ≥ 10, 0.6 ≤ 𝑃𝑟𝑖 ≤ 160
𝑑 𝑖,𝑖

𝑁 = 0.4 𝑓𝑜𝑟 𝑇𝑠 > 𝑇𝑚 𝑜𝑟 𝑛 = 0.3 𝑓𝑜𝑟 𝑇𝑚 > 𝑇𝑠

Where 𝑇𝑠 is the surface temperature and 𝑇𝑚 is the medium temperature.

1.2.9. Prantyl Number

𝐶𝑃 𝑖 𝜇 𝑖
𝑃𝑟𝑖 = (11)
𝐾𝑖

With Reynolds number calculated the same correlations apply and 𝑕o , the convective heat transfer coefficient of
fluid in the outer pipe in 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡2 ℉ 𝑜𝑟 𝑊/𝑚2 0C can be determined from

𝑕 𝑜 𝑑 𝑜 ,𝑖
𝑁𝑢𝑜 = (12)
𝑘𝑜

1.2.10. Energy Balances

Energy in:

𝑑𝑇 𝑖,𝑎
𝑀𝑖 .𝐶𝑃𝑖 . = 𝑞𝑖 . 𝜌𝑖. 𝐶𝑝𝑖 𝑇𝑖,𝑖 − 𝑇𝑖,𝑜 − 𝑈. 𝐴. ∆𝑇𝑙𝑚 (13)
𝑑𝑡

Energy out:

𝑑𝑇𝑜 ,𝑎
𝑀𝑜 . 𝐶𝑝𝑜 . = 𝑞𝑜 𝜌𝑜 . 𝐶𝑝𝑜 𝑇𝑜,𝑖 − 𝑇𝑜,𝑜 + 𝑈. 𝐴. ∆𝑇𝑙𝑚 (14)
𝑑𝑡

1.2.11. Fouling Factor

The fouling factors 𝑅𝑓𝑜 which is the fouling factor outside the inner pipe and 𝑅𝑓𝑖 which is the fouling factor inside
the inner pipe can be checked with standards of tubular exchange manufacturers association or determined
experimentally.

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The performance of a heat exchanger depends on the cleanness of the heat transfer surfaces. Dirt, corrosion and
surface deposits increases the thermal resistance resulting in decreased performance.

This added resistance is usually accounted for by a fouling factor or fouling resistance 𝑅𝑓 which the design
engineer must include along with other thermal resistances when calculating the overall heat transfer coefficient.
Pitts & Sisson (1998) gives the formula for fouling resistance as:
1 1
𝑅𝑓 = − (15)
𝑈 𝑑𝑖𝑟𝑡𝑦 𝑈 𝑐𝑙𝑒𝑎𝑛

Where 𝑅𝑓 is the fouling resistance measured in 𝑚2 𝐾/𝑊 𝑜𝑟 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡 2 ℉.

Udirty is the overall heat transfer coefficient when the heat exchanger is dirty. 𝑈clean is the overall heat transfer
coefficient when the heat exchanger is clean. Note that fouling factor is not a safety factor in design but one of the
resistances to be added when calculating overall heat transfer coefficient.
1.2.12. Effectiveness of the Heat Exchanger

The number of transfer units (NTU) is a procedure for evaluating the performance of heat exchangers. The
advantages of this procedure is that it does not require the evaluation of the mean temperature differences hence an
unknown stream outlet temperature can be determined directly without any iterative calculations.
𝑞 𝑎𝑐𝑡𝑢𝑎𝑙
The effectiveness of the heat exchanger is given by: =∈=
𝑞 𝑚𝑎𝑥

𝐴𝑐𝑡𝑢𝑎𝑙 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑕𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟

(16)
𝑇𝑕𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑕𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟

The maximum possible rate of heat transfer is that which would result if one fluid underwent a temperature change
equal to the maximum temperature difference available – the temperature of the entering hot fluid minus the
temperature of the entering cold fluid. This method uses the effectiveness to eliminate the unknown discharge
temperature and give a solution for effectiveness in terms of (mass, specific heat capacity, Area and overall heat
transfer coefficient).
1.2.13. For a Counterflow Heat Exchanger of Infinite Area.
Heat lost by the hot fluid = Heat gained by Cold fluid Let 𝑚 = 𝑚𝑎𝑠𝑠, 𝐶 = 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑕𝑒𝑎𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦, 𝑡 =
𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒, 𝑕 = 𝑕𝑜𝑡, 𝑐 = 𝑐𝑜𝑙𝑑, 𝐼 = 𝑖𝑛𝑙𝑒𝑡, 𝑜 = 𝑜𝑢𝑡𝑙𝑒𝑡, 𝑞 = 𝑀𝑕 𝐶𝑕 𝑇𝑕 = 𝑀𝑐 𝐶𝑐 𝑇𝑐

𝑞𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑀𝑕 𝐶𝑕 𝑇𝑕𝑖 − 𝑇𝑕𝑜 = 𝑀𝑐 𝐶𝑐 𝑇𝑐𝑜 − 𝑇𝑐𝑖 (17)

The maximum possible heat transfer occurs when the fluid of smaller specific heat capacity undergoes the maximum
temperature difference that is available.
𝑞𝑚𝑎𝑥 = 𝑀𝐶𝑚𝑖𝑛 𝑇𝑕𝑖 − 𝑇𝑐𝑖 (18)

For heat exchangers with unknown discharge temperatures, the basic heat transfer equation is derived to be:
𝑞𝑎𝑐𝑡𝑢𝑎𝑙 =∈. 𝑀𝐶𝑚𝑖𝑛 𝑇𝑕𝑖 − 𝑇𝑐𝑖 (19)

1.2.14. For Parallel Flow Heat Exchanger

𝑀𝐶 𝑇𝑕 𝑖 −𝑇𝑕 𝑜 𝑀𝐶𝑐 𝑇𝑐𝑜 −𝑇𝑐𝑖
∈= 𝑀𝐶 𝑕 = (20)
𝑚𝑖𝑛 𝑇 𝑕 𝑖 −𝑇 𝑐𝑖 𝑀𝐶 𝑚𝑖𝑛 𝑇𝑕 𝑖 −𝑇𝑐𝑖

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Since either the hot fluid or the cold fluid may have 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑚𝑎𝑠𝑠 × 𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑕𝑒𝑎𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦, there
are two possible values of the effectiveness:
𝑇𝑕 𝑖 −𝑇𝑕 𝑒
𝑀𝐶𝑕 < 𝑀𝐶𝑐 : ∈𝑕 = (21)
𝑇𝑕 𝑖 −𝑇𝑐𝑖

𝑇𝑐𝑜 −𝑇𝑐𝑖
𝑀𝐶𝑐 < 𝑀𝐶𝑕 : ∈𝑐 = (22)
𝑇𝑕 𝑖 −𝑇𝑐𝑖

Where subscripts on ∈ designate the fluid which has minimum 𝑀𝑐 .

From the equation:

∆𝑇2 1 1
𝑙𝑛 = −𝑈𝐴 + (23)
∆𝑇1 𝑀 𝑕 𝐶𝑕 𝑀𝑐 𝐶𝑐

It may be written in terms of 𝑀𝑐𝑠 to give

𝑇𝑕 𝑜 −𝑇𝑐𝑜 1 1
𝑙𝑛 = −𝑈𝐴 + (24)
𝑇𝑕 𝑖 −𝑇𝑐𝑖 𝐶𝑕 𝐶𝑐

𝑇𝑕 𝑜 −𝑇𝑐𝑜 𝑈𝐴 𝑀𝐶 𝑕
= 𝑒𝑥𝑝 − 1+ (25)
𝑇𝑕 𝑖 −𝑇𝑐𝑖 𝑀𝐶 𝑕 𝑀𝐶𝑐

From the energy balance equation: equation 17 above.

𝐶𝑕
𝑇𝑐𝑜 = 𝑇𝑐𝑖 + 𝑇𝑕𝑖 − 𝑇𝑕𝑜 (26)
𝐶𝑐

Combining equations 25 and 26 with equation 21& 22 which assumes that the hotter fluid has a minimum value of
𝑀𝑐 , we obtain

1−𝑒𝑥𝑝 − 𝑈𝐴 /𝑀𝐶 𝑕 1+𝑀𝐶 𝑕 /𝑀𝐶𝑐

∈𝑕 = (27)
1+𝑀𝐶 𝑕 /𝑀𝐶𝑐

The minimum values of Mc for the colder fluid is given as:

𝑈𝐴 𝑀𝐶
1−𝑒𝑥𝑝 − 1+ 𝑐
𝑀𝐶 𝑐 𝑀𝐶 𝑕
∈𝑐 = 𝑀𝐶 (28)
1+ 𝑐
𝑀𝐶 𝑕

Equations 27 & 28 may both be expressed as below:

1−𝑒𝑥𝑝 − 𝑈𝐴 /𝑀𝐶 𝑚𝑖𝑛 1+𝑀𝐶 𝑚𝑖𝑛 /𝑀𝐶𝑚𝑎𝑥

∈= (29)
1+𝑀𝐶 𝑚𝑖𝑛 /𝑀𝐶𝑚𝑎𝑥

𝑈𝐴
For the parallel flow heat exchanger, the effectiveness in terms of two dimensionless ratios
𝐶𝑚𝑖𝑛

Is called the number of transfer units (NTU).

𝑈𝐴
𝑁𝑇𝑈 = (30)
𝐶𝑚𝑖𝑛

The number of transfer units (NTU) may be considered as the heat exchanger size factor. Equation (29) contains
only the overall heat transfer coefficient, area, fluid properties and flowrates.

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2.0. METHODS

A. Opto-22 Software
The valves on the double-pipe heat exchanger are electronically controlled, and the data from the thermocouples and
the flow meters are taken via computer. The following steps will explain how to start the software, and what the
various sections of the software mean.
(i) Turn on the computer.
(ii) Click on the icon reading “Shortcut to Heat Exchanger MMI.” This will load the Opto-22 software.
(iii) The first screen that appears will look like this:

Fig. 5: Loading the heat-exchanger software.

(iv) Click on the Heat-Exchanger Menu button. At this time, another menu will come up.

Fig. 6: Selecting the double-pipe heat exchanger

(v) Select the “Double Pipe”.

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(vi) Figure 7 opens up next. This is the Opto-22 interface screen. All the work that is done while the heat
exchanger is operating will be done here. For both the cooling and the water (process) flow the manipulated
variable (MV) is the percent opening of the respective control valves. 100% means that the valve is fully
opened and 0% means that the valve is completely closed. The valve setting is changed by opening up the
green MV and inputting a value of 0-100.

Fig. 7: Opto-22 interface and control screen

(vii) The lower portion of Figure 7 shows values for the six different thermocouple readings,
for the coolant and process flow meters and also for the control valves themselves. The
colors in these boxes correspond with the colors of the lines in the graphs. This Opto
screen provides numerical values and plots the numerical values to the graph. A new
reading is taken and recorded at least every 5 seconds. Old data are saved to a file and are
accessible in this screen.

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B. Using Data in Excel

(i) Open the file in Excel. It is found in the C drive in “double-pipe data”.

Fig. 8: Opening the double-pipe data

(ii) The data are saved in comma-delimited form. So Excel has to convert this to rows and columns.

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Fig.9: Text wizard Step one

Text wizard step one indicates that the data are in delimited form.
Fig. 10: Text wizard step two

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The data are delimited using commas, this is apparent from the preview

Fig. 11: Text wizard step three

The last step in the import wizard is to specify the data format of the columns and create the spreadsheet.

(iii) Once in Excel the data can then be studied and used in any necessary calculations. All the data
(thermocouple readings, flow measurements and % control valve opening) given on the Opto-22
interface are recorded in this style for later use. Data such as this are very useful in the study of
transient behavior.

C. System Start up

Between runs and at startup, the heat exchanger has to be cleaned in order to remove any rust or scale that has built
up in the pipes.
(i) Make sure the computer is on, and the Opto-22 software is running on the double-pipe heat exchanger.
Open both the valves to 100%.
(ii) Open the globe valve to the cold water. Close valve that allows water to the reach the tank. Allow time for
the cooling water to flush the coolant pipe.
(iii) Close the ball valve to the recycle, the tank and to the drain. Open the ball valve that allows mixing of
cooling water and process fluid. This will allow the cooling water to run through the inner pipe and clean
out any debris or deposits.
(iv) Once the tank is about half way full, open the tank valve and the drain valve and allow tank and inner pipe
to drain, repeat this same process until the process fluid looks clean.
(v) Once the fluid is clean, close the tank valve, close the drain valve and proceed to fill the tank.
(vi) When finished, close the valve that allows the cooling water to mix with the process fluid. This will close
the loop to the process. Open the drain valve to allow cooling water to cycle.

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D. Turning on the Steam

(i) Get a ladder, put on thermal resistant gloves and open the steam valve above the heat exchanger.
(ii) Open the inlet steam valve to the exchanger.
(iii) Open the outlet steam (gate) valve.
(iv) The steam trap will capture the steam and condense it. This will control the flow of steam to the exchanger.
The steam will condense as it transfers it’s heat to the process fluid. The steam trap will allow only liquid to
the steam drain.

E. Calibration of the flow meters

Simple calibrations can be made for the flow meters. Calibrated data should be compared not only with the
instrument itself, but when and where possible also with Opto-22. The thermocouples should not be removed from
the heat exchanger, however the thermocouples still need to be calibrated regularly, if and when, necessary
calibration of the thermocouples should take place
(i) Use a bucket or other container that can hold water. The container should have a volume of at least 3
gallons, but not exceed 5 gallons. Obtain a scale that can measure mass up to 10 kg. Obtain a stopwatch.
(ii) Determine what range of flow rates that are necessary to give the required conditions. At least three
separate flowrates should be used.
(iii) Open or close the control valve to give the needed flow rates.
(iv) Record the flow rate both on the computer and on the flow meter; these should be the same.
(v) Have one person record time, one person hold the bucket and one person watch the flow meter to look for
variation in the flow.
(vi) Weigh the empty bucket.
(vii) Fill the bucket from the tank inlet, record the time it takes to fill the bucket.
(viii) Record the temperature of the outgoing stream.
(ix) Weigh the bucket with water. Find the weight of the water.
(x) Determine the flowrate using density of the fluid at the recorded temperature
(xi) Repeat the calibration two to four times.

F. Making Measurements

Once the flow meters have been calibrated and the system is flushed of any loose scaling, measurements can be
made. Depending on the nature of the experiments to be performed, whether they be steady- or unsteady-state, the
following procedure might vary. It is recommended however to first open the control valves to a setting that allows
the type of flow that is needed, whether it be laminar or turbulent. Second is to activate the pump to give the needed
flow in the process fluid. Figure 12 shows the pump control on the west wall that needs to be used. The pump on the
operators left is the one that is used for the double-pipe heat exchanger. Once the pump is activated, wait and see
when the system reaches steady state and then make any necessary changes to the system.

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Fig. 12: The Pump Control Switches

The pump power switch is the switch on the left.

These power switches are located on the wall behind the heat exchanger.

G. Safety

Safety precaution is of utmost importance with any process. At all times operators of the equipment should wear
safety glasses and hardhats, especially when the steam is turned on, or people are working on ladders (with the
steam valves). When opening or closing the steam valves, always wear heat-resistant gloves. After the steam is
turned on, care must be exercised as the water and pipes will become warm. Avoid touching the warm metal. Most
of the critical areas are insulated; however, there are several exposed pipes that can become quite warm. The level of
water in the tank should be kept at least one-third full to decrease the amount of splashing, especially when the water
is hot. As water spills may occur, it is also important to have a mop and bucket on hand whenever the heat
exchanger is used. Clean up any spills immediately to avoid damaging any electronics, especially on the computer
controlling the equipment or the pump. It is important to keep the area surrounding the pump clear. While it is
enclosed and mounted, the pump does require ventilation. Also, never run the pump dry or run it with the process
and with the bypass valve shut. Not only does it wear out the valves and seals, but the pump can also overheat.

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2.1. Operations of Double Pipe Heat Exchangers

When a double pipe heat exchanger is in operation, an operator should periodically check the instrumentation
associated with the heat exchanger. For example, temperature and pressure gauges should be observed to make sure
that their readings are within normal operating ranges.

By checking the temperature gauges on a heat exchanger, an operator can tell the actual temperatures and the
difference in temperature between the fluids entering and leaving the heat exchanger.

The difference in temperature can indicate whether or not proper heat transfer is taking place. For example, a lower
than normal difference in temperature generally means that proper heat transfer is not occurring.

By checking the pressure gauges on a heat exchanger, an operator can get an indication of flow problems. In order
for fluid to flow through a heat exchanger, the inlet pressure must be higher than the outlet pressure. The difference
between the inlet and outlet pressures is called differential pressure. A higher than normal differential pressure can
indicate blockage inside a heat exchanger.

2.2. Operational Problems

Regardless of how a particular double pipe heat exchanger is used, its basic function is to transfer heat from one
fluid to another. Anything that restricts the transfer of heat reduces the efficiency of the heat exchanger and can
cause problems in system operation. Two problems that can interfere with heat transfer in a heat exchanger are
blockage, or fouling, and leakage.

“Fouling” is a general term that describes the buildup of various kinds of deposits on the internal surfaces of a heat
exchanger. Fouling is generally caused by impurities in the fluids passing through a heat exchanger. Impurities, such
as dissolved gases, can react with the metal in a heat exchanger and cause corrosion products to build up. Corrosion
also eats away metal, and it can cause leaks.

When fouling substances accumulate on the pipe walls of a heat exchanger, they form a layer of material that
reduces the effectiveness of heat transfer through the tubes. Excessive buildup on the pipe walls also reduces the size
of the pipe openings and restricts the flow of fluids through the pipes.

Heat exchanger problems are frequently indicated by changes in temperature and pressure that an operator should
notice. For example, if the temperature of the process fluid discharged from a heat exchanger is too high, and the
temperature of the cooling water leaving the heat exchanger is lower than normal, it could mean that deposits are
reducing the amount of heat transfer.

If fouling is bad enough to restrict the passage of fluid through a heat exchanger, pressure gauges should indicate
that the differential pressure has increased above the normal range. Usually, another sign of fouling is a gradual
decrease in flow through the heat exchanger. An operator may be able to observe this gradual decrease by carefully
monitoring instrument indications.

Some procedures may allow a fouled heat exchanger to be operated at higher pressures in order to maintain the
proper rate of flow through it. However, when fouling gets bad enough, the heat exchanger must be cleaned. Some
heat exchangers can be cleaned, without taking them out of service, by backwashing. Backwashing is the reversing
of fluid through the heat exchanger. Generally, backwashing can only be accomplished on the cooling water side of
a heat exchanger. By reversing the flow of cooling water, fouling deposits can be dislodged and washed out of the
heat exchanger.

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“Leakage” in a heat exchanger is usually caused by failure of metal due to overheating, erosion, or corrosion.
Erosion is the wearing away of metal caused by the flow of fluids through heat exchanger tubes. Erosion rates are
affected by factors such as the abrasiveness of the fluid and its temperature and pressure. For example, a fluid that
contains solid particles is more abrasive than a pure fluid. The solid particles coming in contact with the metal of an
exchanger help promote erosion. Erosion can also occur more rapidly as operating temperatures or pressures
increase.

While erosion physically wears away metal, corrosion chemically attacks metal and weakens it. Vibration,
temperature, and pressure contribute to failure of the weakened metal, and help to cause leakage.

One way an operator can tell if a leak exists inside a heat exchanger is by sample testing the lower pressure fluid. If
the fluids have different physical properties, such as water and oil, it may be possible to detect a leak simply by
looking at the sample. If the fluids are very similar, laboratory analysis will be required to tell if the fluid is
contaminated.

2.3. Process Equipment

Williams et al. (2002) gives the following process equipment for the operation of double pipe heat exchanger.

Fig. 13: Pump

This pump is used to pump the fluid from the tank to double-pipe heat exchanger.

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Fig.14: Valve
This valve allows steam to enter the steam pipe in the annulus of the double-pipe heat exchanger.

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Fig. 15: Valve

When this valve is open the cold water can enter the double-pipe heat exchanger.

Fig. 16: Valve (Apollo)

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When the valve (Apollo) on the left is open it allows the cooling water to travel to the drain. When the valve (Watts
Regulator) on the right is open, the process fluid can travel to the drain.

Fig. 17: Control valve

This Control valve is used to control the amount of coolant flow to the heat exchanger.

Fig. 18: Meter

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The meter measures the flow of process fluid coming from the pump.

3.0. DISCUSSION
The driving force for heat exchanger, the mean temperature difference is calculated as logarithmic mean temperature
difference for counter current flow where specific heat and overall heat transfer coefficient is constant. For the
double pipe heat exchanger, the overall heat transfer coefficient is the sum of the inverse of the individual heat
transfer coefficients. The estimated value of the overall heat transfer coefficient is used to calculate the heat transfer
surface area from which the diameter and lengths of both the inner pipe and outer pipe are determined and the length
of straight section and number of bends. The heat exchanger is constructed, installed and operated based on laid
down rules and regulations to enhance efficiency, quality and product yields .

4.0. CONCLUSION
Double pipe heat exchanger design as contained in this technical paper is very straight forward. It is one heat
exchanger pipe inside another, for either counter current flow or parallel flow, the heat exchanger surface area is
determined from the heat exchange duty, log mean temperature difference and the estimated overall heat transfer
coefficient. From this, heat exchanger surface area, the pipe sizes, pipe lengths and the number of bends can be
determined. The performance of the heat exchanger can be checked using the fouling factor and the effectiveness of
the heat exchanger.

5.0. RECOMMENDATION
The double pipe heat exchanger is recommended for use only where small heat transfer area is required. Several
double pipe heat exchangers can be connected in series if a higher capacity is required.

6.0. NOMENCLATURE

Symbol Definition Unit

A surface area for heat transfer ft2 or 𝑚2

𝐴𝑜 Cross sectional area of outer pipe ft2

𝐴𝑖 Cross sectional area of inner pipe ft2.

𝑎𝑖 Cross section of inner pipe 𝑓𝑡 2 𝑜𝑟 𝑚2

𝐶𝑃𝑖 Heat capacity of fluid in the inner pipe 𝐵𝑡𝑢/𝑕𝑟𝑓𝑡 2 ℉ 𝑜𝑟 𝑊/m2 ℃.

𝐶𝑃𝑜 Heat capacity of the fluid in the outer pipe 𝐵𝑡𝑢/𝑙𝑏𝑚 ℉ 𝑜𝑟 𝑊/𝑘𝑔 ℃.

𝑑𝑖,𝑖 Inner diameter of inner pipe ft.

𝑑𝑖,𝑜 Outer diameter of inner pipe ft.

𝑑𝑜,𝑖 Inner diameter of outer pipe 𝑓𝑡 or 𝑚.

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𝑕𝑜 Convective heat transfer coefficient of

fluid in outer pipe, 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡 2 ℉ or 𝑊/𝑚2 ℃
𝑕𝑖 Convective heat transfer coefficient of
fluid in inner pipe 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡 2 0F 𝑜𝑟 𝑊/𝑚2 0C.

𝐾 Thermal conductivity of inner pipe material 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡 2 ℉.

𝐾𝑖 Thermal conductivity of the inner

pipe material 𝐵𝑡𝑢/𝑕𝑟𝑓𝑡 ℉ 𝑜𝑟 𝑊/m2 ℃.

𝑘𝑜 Thermal conductivity of the outer

pipe material 𝐵𝑡𝑢/𝑕𝑟𝑓𝑡 ℉ 𝑜𝑟 𝑊/𝑚℃

𝑙 Total length of pipe 𝑓𝑡 or 𝑚

𝑙𝑛 Natural logarithm.

𝑀𝑖 Mass of fluid in inner pipe 1𝑏𝑚 𝑜𝑟 𝑘𝑔.

𝑀𝑜 Mass of fluid in outer pipe 1𝑏𝑚 𝑜𝑟 𝑘𝑔.

𝑁𝑢𝑜 Nusselt number of fluid in the outer pipe.

𝑁𝑢𝑖 Nusselt number of fluid in inner pipe.

𝑛 Index number.

𝑃𝑟𝑖 Prantyl number of fluid in the inner pipe.

𝑄 Heat duty or heat transferred per unit time 𝑊 𝑜𝑟 𝐵𝑡𝑢/𝑕𝑟

𝑞𝑖 Volumetric flow rate of the fluid in

the inner pipe 𝑓𝑡 3 𝑆 −1 𝑜𝑟 𝑚3 𝑆 −1 .
𝑓𝑡 3
𝑞𝑜 Volumetric flow rate of fluid in the outer pipe 𝑜𝑟𝑚3 𝑆 −1 .
𝑆

𝑅𝑒𝑖 Reynolds number of fluid in the inner pipe.

𝑅𝑓𝑜 Fouling factor outside the inner pipe 𝐵𝑡𝑢/𝑕𝑟 𝑓𝑡 2 0F.

𝑅𝑓𝑖 Fouling factor inside the inner pipe Btu/hr ft2 0F.

𝑇1 Inlet hot fluid temperature. K

𝑇2 Outlet hot fluid temperature K

𝑇𝑚 Temperature at the medium K

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𝑇𝑠 Temperature at the surface K

𝑇𝑖,𝑖 Inlet temperature of fluid in inner pipe ℉ 𝑜𝑟 ℃.

𝑇𝑖,𝑜 Outlet temperature of fluid in inner pipe ℉ 𝑜𝑟 ℃ 𝑜𝑟 °𝐾.

𝑇𝑜,𝑖 Inlet temperature of fluid in outer pipe ℉ 𝑜𝑟℃ 𝑜𝑟 °𝐾.

𝑇𝑜,𝑜 Outlet temperature of fluid in outer pipe ℉ or ℃ or °𝐾.

𝑇𝑖,𝑎 Average temperature of fluid in inner pipe ℉ 𝑜𝑟 ℃ 𝑜𝑟 °𝐾.

𝑇𝑜,𝑎 Average temperature of fluid in inner pipe ℉ 𝑜𝑟 ℃ 𝑜𝑟 °𝐾.

𝑡1 Inlet cold fluid temperature. K

𝑡2 Outlet cold fluid temperature. K

∆𝑇𝑙𝑚 Log mean temperature difference K

U overall heat transfer coefficient 𝐵𝑡𝑢/𝑕 𝑟 𝑓𝑡 2 0F or 𝑊 𝑚2 °𝐾

𝜌𝑖 Density of fluid in the inner pipe 𝑙𝑏𝑚/𝑓𝑡 3 𝑜𝑟 𝑘𝑔𝑚−3 .

𝜌0 Density of fluid in the outer pipe 1𝑏𝑚/𝑓𝑡 3 𝑜𝑟 𝑘𝑔/𝑚3 .

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𝜋 Constant 3.142 𝑜𝑟 7

𝜇𝑖 Viscosity of fluid in the inner pipe 𝑘𝑔𝑚/𝑚. 𝑠.

7.0. REFERENCES

Bengtson H. (2010). Double Pipe Heat Exchanger Design. In: Lamar Stonecypher (Editor),
Double Pipe Heat Exchanger (pp 1 -3) USA: Bright hub engineering Company.
Available: www.brighthubengineering.com Accessed: [20th December, 2014].

Coulson, J.M., Richardson, J.F & Sinnot, R.K. (2009). Chemical Engineering. Vol. 6, 5th edition,
New York: Pergamon Press.

Green, D. W & Robert H. P. (1997). Chemical Engineers’ Handbook. (Seventh Edition)

Singapore: McGrawhill Book Company.

Incropera, F.P., D.P. DeWitt, Fundamentals of Heat and Mass Transfer, John Wiley & Sons,
Inc., pp. 460, 582-612. (1996).

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Pitts, D. & Sisson, L. (1998). Schuams Outline of Theory and Problems on Heat transfer. 2nd
edition, New York: M.C Grawhill,

Tubular Exchanger Manufacturers Association. (1978).Standards of Tubular Exchanger

Manufacturers Association. New York: TEMA

Williams, J. B., Thomas W & Dong-Hoon H. (2002). Double Pipe Heat Exchanger, 1st edition,
Project No. 1H Laboratory Manual, USA: Robert Cox MEB3520

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