EXP2,3,4-Shell and Tube Full

PRACTICAL EXERCISES MANUAL
Unit ref.: TICT Date: February 2016 Pg: 1 / 108
TABLE OF CONTENTS
7 PRACTICAL EXERCISES MANUAL.............................................................................................2

7.1 DESCRIPTION............................................................................................................................... 2
7.1.1 Introduction .................................................................................................................................................... 2
7.1.2 Description of the unit ................................................................................................................................... 3
7.1.3 Description of the process .............................................................................................................................. 8
7.1.4 Practical possibilities ................................................................................................................................... 13
7.1.5 General specifications .................................................................................................................................. 15
7.1.6 Dimensions and weight ................................................................................................................................ 17
7.1.7 Required services ......................................................................................................................................... 18
7.2 THEORY....................................................................................................................................... 19
7.2.1 Introduction .................................................................................................................................................. 19
7.2.2 Overall heat transfer coefficient ................................................................................................................... 20
7.2.3 Heat transfer by convection ......................................................................................................................... 24
7.2.4 Types of flow in a heat exchanger ............................................................................................................... 26
7.2.5 Temperature distribution in exchangers ....................................................................................................... 27
7.2.6 Logarithmic mean temperature difference ................................................................................................... 28
7.2.7 Calculation of the heat transfer coefficient from the rate of heat transfer .................................................... 29
7.2.8 Calculation of the heat transfer coefficient by convection (h) ..................................................................... 30
7.2.9 Obtaining Nusselt number ........................................................................................................................... 31
7.2.10 NTU-effectiveness method for the analysis of a heat exchanger ............................................................. 33
7.3 OPERATION ................................................................................................................................ 36
7.3.1 TICC/TICB unit ........................................................................................................................................... 36
7.3.2 Position of the valves according to the flow direction ................................................................................. 39
7.3.3 Control of the hot water flow ....................................................................................................................... 40
7.3.4 Filling the water tank ................................................................................................................................... 40
7.3.5 Connection of the base unit to the exchanger .............................................................................................. 41
7.4 MAIN INSTRUCTIONS, WARNINGS AND PRECAUTIONS ................................................. 42
7.5 LABORATORY PRACTICAL EXERCISES ............................................................................. 43
7.5.1 Practical exercise 1: Overall energy balance in the exchanger and study of heat losses .............................. 43
7.5.2 Practical exercise 2: Obtainment and representation of the temperature distribution in a shell and tube
exchanger ................................................................................................................................................................... 49
7.5.3 Practical exercise 3: Calculation of the LMTD for a shell and tube exchanger ........................................... 54
7.5.4 Practical exercise 4: Calculation of the overall heat transfer coefficient in a shell and tube exchanger ...... 57
7.5.5 Practical exercise 5: Calculation of the effectiveness of the shell and tube exchanger with the ε-NTU
method… .................................................................................................................................................................... 62
7.5.6 Practical exercise 6: Influence of the flow in the heat transfer. Calculation of Reynolds number in the side
of the tubes ................................................................................................................................................................. 71
7.5.7 Practical exercise 7: Influence of the flow in the heat transfer. Calculation of Reynolds number in the side of
the shell ...................................................................................................................................................................... 76
7.5.8 Practical exercise 8: Obtainment of Prandtl number for the tubes side ............................................................. 82
7.5.9 Practical exercise 9: Obtainment of Prandtl number for the shell side .............................................................. 87
7.5.10 Practical exercise 10: Obtainment of Nusselt number and the heat transfer coefficient by convection (h i) for
the side of the tubes .................................................................................................................................................... 92
7.5.11 Practical exercise 11: Obtainment of Nusselt number and the heat transfer coefficient by convection (h o) for
the side of the shell..................................................................................................................................................... 99
7.6 ANNEXES ................................................................................................................................... 107
7.6.1 Annex I: Water table properties ................................................................................................................. 107
7.6.2 Annex II: Plots ........................................................................................................................................... 108
7 PRACTICAL EXERCISES MANUAL
7.1 DESCRIPTION
7.1.1 Introduction
A heat exchanger is any device where a heat exchange between two fluids
separated by a metal wall is verified. This metal wall represents the heat transfer
surface and its geometry can be of any shape.
The shell and tube heat exchanger is the most widely used in industry. It
adapts to fluids at high and low pressures, high and low temperatures and constitutes
the most important part of heat transfer equipment without combustion in chemical
processes plants. Besides, they are compact and efficient, and their high velocities
improve the heat transfer rate.
The shell and tube heat exchanger designed by EDIBON S.A. allows the
study of heat transfer between the hot water that flows by an inner tube and the cold
water that flows by the annular area between the inner tube and the outer tube, called
shell. The unit allows to work under different flow conditions, from laminar to
turbulent. At the same time, it can vary the flow direction to work either in
countercurrent or in parallel.
7.1.2 Description of the unit
7.1.2.1 Base unit
 TIUS unit
 TIUSB unit
1. D-1: tank made of stainless steel to heat the fluid of the hot circuit. Inside it
includes:
- Heating element, AR-1.
- Level sensor, AN-1, to guarantee a specific level in the tank.
- Temperature sensor, ST-16, of the water in the tank.

2. RP-1: pressure regulator. It allows to regulate the water inlet pressure. The
unit is supplied with the regulator adjusted to 0.7 bars approx. to avoid
overpressures in the unit it will supply.
3. AB-1: hot water impeller centrifugal pump that allows the variation of the
flowrate that circulates through the hot circuit.
4. VR-1: regulation valve of the hot circuit water bypass. It is supplied already
adjusted to a minimum flowrate, which is the one recommended by the
manufacturer and the one that guarantees a good operation of the unit. It is
sealed.
5. VR-2: regulation valve of the water flowrate of the cold circuit.
6. VR-3: regulation valve of the water flowrate of the hot circuit.
7. V-1 and V-6: passing ball valve and draining ball valve of the hot water
circuit of the base unit.
8. V-2, V-3, V-4 and V-5: passing ball valves that allow to vary the direction of
the flow of the cold circuit towards the exchanger.
Instrumentation:
- SC-1: flow sensor that measures the water flowrate of the hot circuit.
- SC-2: flow sensor that measures the water flowrate of the cold circuit.
 Particularities of the TIUSB unit:
9. C-1: flow meter that measures the water flow of the hot circuit.
10. C-2: flow meter that measures the water flow of the cold circuit.
7.1.2.2 TICT, shell and tube heat exchanger
11. V-7: passing and draining valve of the water of the hot circuit at the inlet of
the exchanger.
12. V-8: hot water outlet circuit. It ends in the passing and draining valve V-8.
13. V-9: passing and draining valve of the water of the cold circuit at the inlet of
the exchanger (in parallel flow) and at the outlet of the exchanger (in
countercurrent flow).
14. V-10: passing and draining valve of the water of the cold circuit at the inlet
of the exchanger (in countercurrent flow) and at the outlet of the exchanger
(in parallel flow).
15. P-1: two purge valves that allow to release air from the hot circuit.
16. P-2: four purge valves that allow to release air from the cold circuit.
Instrumentation:
- ST-1: temperature sensor of the hot water at the inlet of the exchanger.
- ST-2: temperature sensor of the hot water at the outlet of the exchanger.
- ST-3: temperature sensor of the water in the cold circuit at the inlet of the
exchanger (in parallel flow) and outlet of the exchanger (in countercurrent
flow).
- ST-4: temperature sensor of the water in the cold circuit at an intermediate

point of the exchanger.


- ST-7: temperature sensor of the water in the cold circuit at the inlet of the
exchanger (in countercurrent flow) and outlet of the exchanger (in parallel
flow).
7.1.3 Description of the process
7.1.3.1 Base unit

The base unit TIUS (TIUSB) fulfills the following functions:
1. Heating of water with the heating element AR-1 and measurement of the
temperature of the thermostatic bath water.
2. Measurement of the hot water flow.
3. Measurement of the cold water flow.

4. Pumping of the hot water.
5. Variation of the direction of the cold water flow. It can work either in
parallel or countercurrent.
7.1.3.2 TICT: Shell and tube heat exchanger
The shell and tube heat exchanger, TICT, consists of 21 tubes arranged as a
square through which a water flow from the hot circuit of the base unit TIUS (TIUSB)
circulates. The cold circuit water flows by the annular side between the shell and the
tubes.
The exchanger has 7 thermocouples distributed between the hot and cold
circuits, in which the temperature at the inlet, outlet and intermediate points of the
exchanger are measured.
7.1.3.3 TICT in countercurrent flow
Hot water circuit
Hot water flows along a closed circuit. A heating element, AR-1, immersed
in the tank, heats water up to a specific temperature, ST-16. Water leaves the tank and
is impelled by a pump, AB-1. Part of the water enters the exchanger and a minimum
part returns to the tank through a bypass. There is a valve in the bypass to regulate the
hot water flow, VR-1. This valve is set to a flowrate recommended by the
manufacturer for the correct use of the unit. The water is cooled at the outlet of the
exchanger and returns to the heating tank. Before entering this heating tank, the fluid
passes through a flow sensor, SC-1 (flowmeter C-1), where the water flow of the hot
circuit that flows through the heat exchanger is measured.
Cold water circuit
The water of the cold circuit comes from the main network, crosses a
regulation valve, VR-2, through which the water flow of the cold circuit that enters the
exchanger can be regulated. Water of the cold circuit crosses a pressure regulator too,
RP-1, programmed to 0.7 bar approx. to avoid overpressures in the unit. Before
entering the exchanger, water passes through a flow sensor SC-2 (flowmeter C-2) to
measure the cold water flow that enters the exchanger. Then, water enters the
exchanger, through which it is heated, leaves the exchanger and is directed to the
drain.
Cold water can enter the exchanger through both ends, to arrange flow in
countercurrent the inlet will be the opposite to that of the hot circuit.
7.1.3.4 TICT in parallel flow
The description of the process is the same than for countercurrent flow,
with the difference that for parallel flow the cold circuit fluid and the hot circuit fluid
enter the exchanger in the same direction.
7.1.4 Practical possibilities
- Overall energy balance in the exchanger and study of heat losses in parallel
flow.
- Overall energy balance in the exchanger and study of heat losses in

countercurrent flow.
- Obtainment and representation of the temperature distribution in a shell and

tube exchanger for parallel and countercurrent flow.
- Calculation of the logarithmic mean of the temperatures for parallel flow.
- Calculation of the logarithmic mean of the temperatures for countercurrent

flow.
- Calculation of the overall heat transfer coefficient (U) for parallel flow.
- Calculation of the overall heat transfer coefficient (U) for countercurrent

flow.
- Determination of the effectiveness of the exchanger. ε-NTU method for

parallel flow.
- Determination of the effectiveness of the exchanger. ε-NTU method for

countercurrent flow.
- Influence of the flow in the heat transfer. Calculation of Reynolds number for
the fluid that flows by the side of the tubes, both for countercurrent and
parallel flow.
- Influence of the flow in the heat transfer. Calculation of Reynolds number for
the fluid that flows through the shell, both for countercurrent and parallel
flow.
- Obtainment of Prandtl number for the side of the tubes, both for
countercurrent and parallel flow.
- Obtainment of Prandtl number for the side of the shell, both for
- Calculation of Nusselt number for the side of the tubes, both for
- Calculation of Nusselt number for the side of the shell, both for
- Obtainment of the heat transfer coefficient by convection for the side of the
tubes (hi), both for countercurrent and parallel flow.
- Obtainment of the heat transfer coefficient by convection for the side of the
shell (ho), both for countercurrent and parallel flow.
7.1.5 General specifications
7.1.5.1 Base unit
- Tank made of stainless steel (30 l.) equipped with:
o Electric heating element AR-1. Power: 3000 W.
o Level switch AN-1.
o Temperature sensor ST-16.
o Cover made of stainless steel with orifice for water level visualization.
o Drain valve to drain the water from the heating tank.
- Impeller pump AB-1. Range: 0-2.5 l/min (this range might vary depending
on the exchanger coupled to the base unit due to pressure drops).
- Pressure regulation valve RP-1.
- 6 ball valves for the passage and draining of the water flowing through the
hot and cold circuits between the base and the exchanger.
- 4 flexible tubes, which connect the base unit with the heat exchanger.
 Particular specifications for the TIUS unit
- 2 flow sensors, SC-1 and SC-2. Measuring range: 0.25-6.5 l/min.
 Particular specifications for the TIUSB unit
- 2 flowmeters, C-1 and C-2. Measuring range: 0.2-2 l/min.
7.1.5.1 TICT exchanger
 Exchanger consisting of 21 tubes made of stainless steel, arranged as a

square, through which hot water flows.
 Inner tube
 Inner diameter: Di = 810 3 m
 Outer diameter: Do= 1010 3 m
 Shell
 Inner diameter: Dic, 0.148 m
 Outer diameter: Doc, 0.160 m
- Exchange length of each tube, L = 0.566 m.

- PT, distance from the center of one tube to the center of another tube (m).
PT = 0.025 m.
- C, space between tubes (m). C = 0.015m.
- B, space between baffles (m). B= 0.100 m.
- 7 “J” type thermocouples to measure the temperature both in the hot and
cold circuits.
- 4 ball valves for the passage and draining of the hot water and cold water
from the exchanger to the base unit (TIUS/TIUSB).
7.1.6 Dimensions and weight
BASE UNIT
Net weight: 30 Kg
Height: 400 mm
Width: 1100 mm
Depth: 650 mm
HEAT EXCHANGER
Net weight: 20 Kg
Height: 200 mm
Width: 1000 mm
Depth: 500 mm
7.1.7 Required services

- Power supply: 220V 50 Hz (110 V 60 Hz).
- Tap water supply.
- Drain.
7.2 THEORY
7.2.1 Introduction
Heat is energy in transit due to a temperature difference. Whenever there is a

temperature difference in one medium or among several media, heat transfer occurs.
There are three different types of heat transfer processes: conduction, convection and
radiation.
 Conduction: it is the heat transfer through solids and stationary fluids.

Conduction physical mechanism is the energy diffusion originated from the interaction
among molecules of the medium.
 Convection: it is the heat transfer between a surface and a fluid in motion at

different temperatures. It is a consequence of the superposition of two physical
phenomena, energy transported by the random movement of the molecules (diffusion)
and energy transported by the macroscopic movement of the fluid (a great number of
molecules moving together).
 Radiation: it is the energy generated by changes in the electronic

configuration of atoms or molecules and transported by electromagnetic waves or
photons. Unlike conduction and convection, radiation is independent from matter for
its propagation, being more effective under vacuum conditions.
A heat exchanger is a device designed by mankind for the heat transfer

between two fluids at different temperatures separated by a solid wall.
There are several criteria (not just one) for heat exchangers classification:
their geometry, the types of flow, the flow conditions, etc.
There is a brief classification of heat exchangers below:

 According to their geometry
- Concentric tubes heat exchanger.
- Shell and tube heat exchanger.
- Plate heat exchanger.
- Coil heat exchanger.
- Jacketed heat exchanger with stirrer.
- Bayonet tube heat exchanger.
 According to the type of flow
- Parallel flow exchanger.
- Countercurrent flow exchanger.
- Cross flow heat exchanger.
 According to the flow conditions
- Laminar flow exchanger.
- Transient flow exchanger.
- Turbulent flow exchanger
7.2.2 Overall heat transfer coefficient
To represent the overall heat transfer phenomenon between the fluids in the
exchanger, the thermal resistances from each medium must be taken into account.
The heat flow, in its way from the hot fluid to the cold fluid, has to
overcome the resistance exerted by the boundary layer of the hot fluid, the resistance
exerted by the separation wall and the resistance exerted by the boundary layer of the
cold fluid, as it can be observed in figure 1.
Temperature Wall of the copper tube

distribution
Cold
Hot fluid q fluid
Ts,c Ts,f T,f

T,c
x 1
1
KA hc Ac
hh Ah
Figure 1: Overall heat transfer phenomenon
These three resistances arranged in series form a total resistance (R t), which
is the addition of each one.
Where:
- Ah  area of the tube surface in contact with the hot fluid (m2).
- Ac  area of the tube surface in contact with the cold fluid (m2).
- T,c  mean temperature of the hot fluid (K).
- T,f  mean temperature of the cold fluid (K).
- Ts,c  temperature of the surface of the tube in contact with the hot fluid
(K).
- Ts,f  temperature of the surface of the tube in contact with the cold fluid
(K).
- hh  convection coefficient of the hot fluid (W/m2 K).
- hc  convection coefficient of the cold fluid (W/m2 K).
- k  thermal conductivity of copper (W/m K).
- A  mean area of the copper tube (m2).
- x  thickness of the copper tube wall (m).
The heat transfer rate will be:
T, h  T, c T, h  T, c

q 
Rt 1 x 1
 
hh  Ah k  A hc  Ac
The overall heat transfer coefficient, U, is defined as a factor that for a given
geometrical and hydrodynamic configuration provides the value of the total heat
transferred, multiplying it by the exchange area and the mean temperature difference
between
q  U  A  (T, h  T, f )
Where:
- q  heat transfer rate (W)
- U  overall heat transfer coefficient (W/m2 K)
- A  total area of heat transfer (m2)
- T,c  average temperature of the hot fluid (K)
- T,f  average temperature of the cold fluid (K)
During the normal operation of the exchanger, the fluids transport impurities
that, as time passes, adhere to the surface, forming an additional layer that increases
the total thermal resistance. As there are two fluids, two additional resistances, called
pollution resistances, are generated. They are variable, since they increase with the
operation time, passing from a zero value when the exchanger is new to a maximum
value at the end of its useful life. The pollution resistances can only be known
empirically, since their nature and thickness is difficult to ascertain.
The terms with greatest influence on the total thermal resistance value are
the convection terms. Since the diameters are specified, it will be fundamental to
determine heat transfer coefficient by convection (h) in order to predict the heat
exchange.
7.2.3 Heat transfer by convection
Heat transfer by convection is characterized for being produced between a

surface and a fluid in motion at different temperatures.
Heat transfer by convection can be classified as:
- Forced convection. It is produced when external source, such as a fan, a

pump or the atmospheric wind, cause the flow.
- Natural convection. It takes place when the flow is induced by buoyancy

forces, which are a consequence of density differences caused by
temperature variations in the fluid.
A consequence of the fluid-surface interaction is the formation of a region in

the fluid in which velocity varies from zero at the surface to an infinite value
associated with the fluid. This is the hydrodynamic boundary layer. Besides, if the
temperature between the surface and the fluid changes, a thermal boundary layer
appears, where the temperature changes from the temperature in the surface to the
temperature in the external side of the fluid. 99% of the heat transfer between the
surface and the fluid takes place in this thin layer.
The first step in the treatment of heat transfer by convection is to determine

whether the hydrodynamic boundary layer is laminar or turbulent, since the heat
transfer rate depends strongly on this condition.
Under laminar condition, the fluid movement is ordered and it is possible to

identify the flux lines along which the particles move. The laminar fluid is associated
with low Reynolds numbers, that is to say, the ratio between the inertia and viscosity
forces is low. This way, the disturbances in the fluid (originating from the surface
roughness or by its own free current) are quickly dissipated, maintaining an ordered
flow (laminar).
If Reynolds number is high, the inertia forces are big enough as to magnify
the disturbances produced in a laminar flow, generating vortexes that indicate the
appearance of the turbulent condition in the fluid. Irregular movement and random
fluctuations in the velocity characterize the turbulent condition.
Due to the fact that the diffusivity of the vortexes is much bigger than the
molecular diffusivity in the laminar condition, the velocity and the temperature
profiles in the boundary layer core are more uniform in the turbulent condition and,
therefore, the temperature and velocity gradients are much bigger.
As a consequence, the heat transfer rate is much bigger in turbulent flows

than in laminar flows.
Regardless of whether there is a laminar or turbulent condition, the heat

transfer rate by convention between a surface and a fluid is given by Newton´s law of
cooling, expressed as:
q = A h (T s  T )
Where:
- q  heat transfer rate (W)
- h  coefficient of heat transfer by convection (W/m2 K)
- A  area of heat transfer (m2)
- Ts  temperature on the surface (K)
- T  temperature in the fluid (K)

7.2.4 Types of flow in a heat exchanger
There are different types of flow in a heat exchanger:
- Parallel flow.
- Countercurrent flow.
- Cross flow.
In parallel flow, the hot and cold fluids enter and leave through the same end
and circulate in the same direction. On the other hand, in countercurrent flow, the
fluids enter and leave through opposite ends and circulate in opposite directions.
Figure 2 shows both types of flow.
Figure 2: Parallel flow (left) and countercurrent flow (right)

In cross flow, a gas passes perpendicularly through some fins or a bundle of tubes,
where a hot fluid flows, as it is shown in figure 3.
Figure 3: Cross flow

7.2.5 Temperature distribution in exchangers
The following figure shows the temperature distribution of an exchanger in

parallel and countercurrent flow:
temperature temperature
Tc, e Tc, e
hot
Tc, s T1 hot
T1 T2 Tc, s

Tf, s Tf,s
T2
cold cold
Tf, e
Tf,e
0 L 0 L
position position
PARALLEL FLOW COUNTERCURRENT FLOW
Figure 4: Temperature distribution in exchangers
Where:
- Tc,e  temperature of the hot fluid at the inlet of the exchanger.
- Tc,s  temperature of the hot fluid at the outlet of the exchanger.
- Tf,e  temperature of the cold fluid at the inlet of the exchanger.
- Tf,s  temperature of the cold fluid at the outlet of the exchanger.
In the parallel flow exchanger, the hottest zone of the hot fluid exchanges
heat with the coolest zone of the cold fluid at the inlet area.
At the beginning the heat transfer is big, since the temperature difference is
great; but this difference falls very quickly along the exchanger, approaching
asymptotically to zero.
It is important to say that, for this type of exchangers, the outlet temperature
of the cold fluid never exceeds the outlet temperature of the hot fluid.
In countercurrent flow, the hottest zone of the hot fluid exchanges heat with
the hottest zone of the cold fluid and the coldest zone of the hot fluid with the coldest
zone of the cold fluid. This configuration gives a good heat transfer both between the
hot parts of both fluids at one end and the cold parts at the other end. Besides, the
outlet temperature of the cold fluid may exceed the outlet temperature of the hot fluid.
7.2.6 Logarithmic mean temperature difference
As it has been seen, the temperature difference between the fluids changes
along the exchanger. This is why it is advisable to define a mean temperature value
(Tm).
From the analysis developed in most books about heat transfer, we can find
that the appropriated mean temperature difference is a logarithmic mean temperature
difference (Tlm), defined in the following equation:
T1  T2
Tlm 
 T 
ln  1 
 T2 
Being for parallel flow:
T1 = Tc,e  Tf,e and T2 = Tc,s  Tf,s

Being for countercurrent flow:
T1 = Tc,e  Tf,s and T2 = Tc,s  Tf,e
7.2.7 Calculation of the heat transfer coefficient from the rate of heat transfer
Two important relations for the analysis of a heat exchanger are the overall
energy balances, both of the hot fluid and the cold fluid. Neglecting the changes of
potential and kinetic energy along the exchanger, we have:
 General heat transfer rate from the hot fluid:
qc = mc Cpc (Tc,e  Tc,s)
 General heat transfer rate from the cold fluid:
qf = mf Cpf (Tf,s  Tf,e)
Where:
- mc  mass flow of the hot fluid (g/s).
- mf  mass flow of the cold fluid (g/s).
- Cpc  specific heat capacity of the hot fluid (J/g.K).
- Cpf  specific heat capacity of the cold fluid (J/g.K).
- Tc,e  temperature of the hot fluid at the inlet of the exchanger.
- Tc,s  temperature of the hot fluid at the outlet of the exchanger.

- Tf,e  temperature of the cold fluid at the inlet of the exchanger.
- Tf,s  temperature of the cold fluid at the outlet of the exchanger.
In theory, qc should be the same as qf but as heat transfer is performed from the
hot fluid to the cold fluid the value of qc will be used to calculate the overall heat
transfer coefficient.
qc = U A Tlm
7.2.8 Calculation of the heat transfer coefficient by convection (h)
To deal with the calculation of the coefficient h, we have to take into

account the dimensional analysis of the equations of Navier Stokes of fluids
mechanics. These results indicate that the dimensionless temperature is a function of
Reynolds number (NRe), Prandtl number (NPr) and the dimensionless geometry.
If Nusselt number (NNu) is defined as the dimensionless temperature gradient

on the surface, it can be said that the NNu is a function of NRe, NPr and the
dimensionless geometry.
NNu = f (NRe, NPr, dimensionless geometry)
Where:
 u  D    Cp
N Re  and N Pr  
  kf
Siendo:
-   density of the fluid (kg/m3)

- u  mean velocity of the fluid in the cross section of the tube (m/s)
- D  diameter of the tube (m)
-   dynamic viscosity of the fluid (kg/m s)
-   kinematic viscosity of the fluid (m2/s)
-   thermal diffusivity of the fluid (m2/s)
- Cp  specific heat capacity of the fluid (kJ/kg K)
- kf  thermal conductivity of the fluid (W/m K)
Note: since the conditions of the flow vary from one point to another on the
surface, the coefficient h also varies along the surface. Therefore, a mean coefficient of
convection is taken, integrating the local coefficient of convection in the entire surface.
This mean value will be the one employed to obtain the mean Nusselt number and the
mean heat transfer rate, which will be the variables used in this study.
On the other hand, from Newton’s law of cooling and the dimensionless
analysis the NNu can be related to the coefficient h:
N Nu  k f
h
D
7.2.9 Obtaining Nusselt number
The easiest method is to use empirical correlations obtained by different

authors from measurements made in the laboratories. These correlations have the
following algebraic form:
NNu = C (NRe) m (NPr) n
The values of C, m and n are independent of the fluid nature, but they
change with the nature of the surface geometry and the type of flow of the exchanger.
The correlations most used in bibliography are based on the type of

geometry of the exchangers and on the flow conditions for each type of exchanger. A
classification of the empirical correlations is expressed below.
 Smooth tubes
- Turbulent condition: NNu = 0.023. (NRe)0.8 * (NPr)n
n = 0.4, if there is heating.
n = 0.3, if there is cooling.
- Laminar condition: NNu = 1.86. [NRe*NPr*(d/L)]1/3 * (μ/ μw)0.14
When [NRe*NPr*(d/L)] >10.
 Flat plates: NNu = 0.28. (NRe)0.65 * (NPr)0,4
When 700 > NRe > 25000
 Jacketed vessel exchanger:
NNu = 0.36 *(NRe)0.67 * (NPr)1/3 * (µ/µw)-0,14 (for the vessel)
 Vessel exchanger with coil:
NNu = 0.023*(NRe)4/5*(NPr0.4)*(µ/µw)0.14*[1 + 3.5*(Di/dc)] (for the coil)
NNu = 39*(NRe)0.5*(NPr)0.3*(µ/µw)0.14 (for the vessel)

 Shell and tube
NNu = 0.36*(NRe)0.55*(NPr)0.3 (shell)
NNu = 0.023. (NRe)0.8 * (NPr)n (tubes)
*Note: the physical properties of the fluid in the previous correlations are based on the
average of the mean temperature between the inlet and the outlet of the exchanger.
7.2.10 NTU-effectiveness method for the analysis of a heat exchanger
If the outlet temperatures of the exchanger are not known, to calculate the
heat transfer rate from the logarithmic mean temperature difference the problem
should be solved by iteration, starting from an approximate value of one of the
temperatures. This method would be slow and expensive. In these cases the NTU-
effectiveness method is preferred.
First, the effectiveness is defined as the quotient between the really

exchanged heat and the maximum that could be transferred in an infinite area
exchanger with countercurrent flow.
qreal

qmax
Where:
- qmax = mc Cpc (Tc,e  Tf,e) if mc Cpc > mf Cpf because the hot fluid would
experience the greatest temperature change.
- qmax = mf Cpf (Tc,e  Tf,e) if mf Cpf > mcCpc because the cold fluid would
experience the greatest temperature change.
Being (Tc,e  Tf,e) the maximum temperature difference possible suffered by one of the
two fluids.
Therefore, the effectiveness will be:
Tc,e  Tc , s
 if mc Cpc > mf Cpf
Tc ,e  T f ,e
Tf,s  T f ,e
 if mf Cpf > mc Cpc
Tc ,e  T f ,e
The number of transfer units (NTU) is a dimensionless parameter widely

used for the analysis of heat exchangers and is defined as:
UA
NTU 
(m  Cp ) min
On the other hand, the capacity ratio (C R) is defined as:
(m  Cp ) min
CR 
(m  Cp ) max
Expressing  as a function of CR and NTU the following plot is obtained:

Figure 5: ε-NTU plots for parallel flow (left) and countercurrent flow (right)
Once the effectiveness is calculated, the temperatures at the outlet of the

exchanger will be:
Tc,s = Tc,e   (Th,e  Tc,e)

if mc Cpc < mf Cpf
Tf,s = Tf,e + CR (Th,e  Th,s)
Tf,s = Tf,e +  (Th,e  Tc,e)

if mf Cpf < mc Cpc
Tc,s = Tc,e  CR (Tc,s  Tc,e)
7.3 OPERATION
7.3.1 TICC/TICB unit
 TICC unit in countercurrent-parallel flow.
1. AR-1 ON/OFF button: switches on/off the heating element of the heating tank.
2. AR-1 PID control. A set-point value for the temperature ST-16 must be selected.
It will indicate the temperature to which the heating tank D-1 will be heated.
3. Knob for the flow control and regulation of the AB-1 pump, varying from 0 to
100%.
4. Tab where the following calculations performed directly by the software are
visualized:
- Value of the dimensionless numbers (NNu, NRe, NPr, ε, NTU).
- Values of heat flows of the hot circuit (qc), the cold circuit (qf) and heat
losses, coefficient (U), coefficient (h).
5. Button to change the operation configuration either in countercurrent or parallel.

 TICB unit in countercurrent-parallel flow.
1. AB-1 ON/OFF button: switches on/off the impeller pump.
2. SENSOR SELECTOR: select among different temperature sensors from which

the working temperature wants to be known.
3. Display or viewer of the temperature selected in the temperature selector.

4. Heating element (ST-16) temperature controller. It allows the selection and

control of the thermostatic bath heating temperature.
7.3.2 Position of the valves according to the flow direction
 Position of the valves for countercurrent flow
For countercurrent flow, the valves of the cold circuit must be positioned as
follows:
- V-3, V-4, V-9 and V-10 must be open.
- V-2 and V-5 must be closed.
The valves of the hot circuit must be positioned as follows:
- V-7 and V-8 must be open.
 Position of the valves for parallel flow
For parallel flow, the valves of the cold circuit must be positioned as follows:
- V-3 and V-4 must be closed.
- V-2, V-5, V-9 and V-10 must be open.
The valves of the hot circuit must be positioned as follows:
- V-7 and V-8 must be open.

7.3.3 Control of the hot water flow
There are two ways to perform the control of the flow:
- TICC: opening the valve VR-3 fully and varying the flow with the actuator
of the pump AB-1 from 0 to 100%.
- TICB: setting the button of the pump AB-1 to ON position and regulating
the flow of hot water with the valve VR-3.
7.3.4 Filling the water tank
Before filling the tank, make sure that the drain valve is closed.
To fill the hot water tank, introduce a rubber hose from the mains to the
tank. For that purpose, remove the tank’s cover or leave the cover and introduce the
pipe through the orifice of the upper part of the tank’s cover.
When the water level reaches the level switch, the tank will be filled. This
operation must be carefully performed.
Note: demineralized or distilled water is recommended for the operation of this unit.
Thus, problems such as the rusting or flaking of the tank will be prevented.
Figure 6: Filling of the tank
7.3.5 Connection of the base unit to the exchanger
To connect the base unit to the exchanger, four flexible tubes are supplied to
guarantee the water flow through the unit. These tubes must be connected from one of
the base unit connections with the connections of the exchanger. Connection 1 of the
base unit will be connected to connection 1 of the exchanger. Proceed the same way
with the other three flexible tubes.
To adjust one connection of the flexible tube you just need to screw the end
of the tube to the connection with an appropriate wrench.
7.4 MAIN INSTRUCTIONS, WARNINGS AND PRECAUTIONS
- Avoid touching the heating tank, it reaches temperatures around 70ºC.
- Do not open the purge valve of the heating tank while the tank is full.
- Do not remove the cover of the tank during the performance of the practical
exercises.
- Check the correct position of the valves before starting each practical exercise.
- Take into account that:
 For the TICC unit, the regulation valve VR-3 must be totally open and
the flow of the hot fluid must be regulated with the control button of
the AB-1 pump’s flow, which varies from 0 to 100%.
 For the TICB unit, the flow of the hot fluid is regulated with the
regulation valve VR-3, so that AB-1 pump’s button must be set to ON
position.
7.5 LABORATORY PRACTICAL EXERCISES
7.5.1 Practical exercise 1: Overall energy balance in the exchanger and study of
heat losses
7.5.1.1 Objective
The objective of this practical exercise is to perform the overall energy

balance in the exchanger calculating the heat flow of the hot fluid, the heat flow of the
cold fluid and the heat losses generated in the exchanger.
7.5.1.2 Required elements
- Base unit (TIUS/TIUSB)
- Shell and tube heat exchanger (TICT)
7.5.1.3 Practical procedure
1. Check that the valves of the hot and cold circuit are correctly positioned for the
performance of the practical exercise in countercurrent flow configuration,
according to the operation section.
2. Check that the water heating tank is full of water above the level switch AN-1.
3. Switch on the heating element AR-1 and set the temperature of the heating tank
ST-16, according to the operation section, to 45ºC.
4. Switch on the impeller pump AB-1 and set a flowrate for the hot circuit SC-1 or
(C-1), as it is indicated in the operation section.
5. Set a flowrate for the cold circuit SC-2 or (C-2), with VR-2, until the system
stabilizes to a temperature of 45ºC in ST-16.
6. Record the temperature measurements (ST-1, ST-2, ST-3, ST-7, ST-16) and
water flowrates SC-1 or (C-1) and SC-2 or (C-2) in the worksheet.
7. Repeat steps from 3 to 6, keeping constant the flow value SC-1 or (C-1) and the
flow value SC-2 or (C-2) for different temperatures of the water in the tank, ST-
16: 50ºC, 55ºC and 60ºC.
8. After performing the measurements, calculate the heat flow of the water in the
hot circuit (qc), the heat flow of the water in the cold circuit (qf) and the heat
losses produced in the exchanger.
o The equation below is used to calculate the heat flow of the water in the hot
circuit (qc):
qc = mc * Cpc * (Tc,e – Tc,s)
Where:
- mc  mass flow of water in the hot circuit (g/s)*
* The water flow is measured by SC-1 or (C-1). The flowrate measured

is expressed in (l/min), so that this value will be converted by the water
density (ρwater) to the mean temperature between the value of Tc,e and Tc,s
of the exchanger (ST-1 and ST-2 respectively).
mc  l g 1 min g
 ( ) 
min l 60s s
- Cpc  specific heat of water to the mean temperature between the value of
Tc,e and Tc,s of the exchanger (J/g.K).
- Tc,e  inlet temperature of the water from the hot circuit to the exchanger,
measured by ST-1 (K).
- Tc,s  outlet temperature of the water from the hot circuit of the
exchanger, measured by ST-2 (K).
o The equation below is used to calculate the heat flow of the water in the cold
circuit (qf):
qf = mf * Cpf * (Tf,s – Tf,e)
Where:
- mf  mass flow of water in the cold circuit (g/s)*
* The water flow is measured by SC-2 or (C-2). The flowrate measured

is expressed in (l/min), so that this value will be converted by the water
density (ρwater) to the mean temperature between the value of Tf,e and Tf,s
of the exchanger (ST-3 and ST-7 respectively).
l g 1 min g
mf   ( ) 
min l 60s s
- Cpf  specific heat of water of the cold circuit to the mean temperature
between the value of Tf,e and Tf,s of the exchanger (J/g.K).
- Tf,e  inlet temperature of the water from the cold circuit to the
exchanger, measured by ST-7 (in countercurrent flow) and measured by
ST-3 (in parallel flow), measured in (K).
- Tf,s  outlet temperature of the water from the cold circuit to the
exchanger, measured by ST-3 (in countercurrent flow) and measured by
ST-7 (in parallel flow), measured in (K).
9. To calculate heat losses, subtract the value of the heat flow of the hot circuit
from the value of the heat flow of the cold circuit. Obtain the values shown in
the worksheet for countercurrent flow.
10.Repeat steps 1 - 9 changing the flow direction and selecting the parallel flow
configuration, as it is indicated in the operation section, keeping both the flow of
the hot fluid SC-1 or (C-1) and the flow of the cold fluid SC-2 or (C-2) constant.
Obtain the data for the parallel flow configuration.
7.5.1.4 Worksheet
Student: ________ Year: __________
Type of flow: _____________
Experiment 1 Experiment 2 Experiment 3 Experiment 4

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
SC-1 or (C-1) (l/min)
SC-1 or (C-1) (g/s)
SC-2 or (C-2) (g/s)
Cpc (J/g.K)
Cpf (J/g.K)
qc (W=J/s)
qf (W=J/s)
Losses (W=J/s)
Student: ________ Year: __________
Conclusions:
1. Observe the heat loss values obtained, both for countercurrent and parallel flow.
Which are the differences between both of them? Explain your answer.
7.5.2 Practical exercise 2: Obtainment and representation of the temperature

distribution in a shell and tube exchanger
7.5.2.1 Objective
The objective of this practical exercise is to obtain and plot the temperature
distribution in a shell and tube exchanger for countercurrent and parallel flow,
knowing the values of the inlet and outlet temperatures of the hot and cold fluids and
the intermediate temperatures inside the exchanger.
7.5.2.3 Experimental procedure
6. Record the temperature measurements (ST-1, ST-2, ST-3, ST-4, ST-5, ST-6 ST-
7, ST-16) and water flowrates SC-1 or (C-1) and SC-2 or (C-2) in the
worksheet.
7. Plot the temperature distribution of the hot and cold circuits along the
exchanger, for countercurrent flow, taking into account that the distances
between temperature sensors are:
 Countercurrent flow
Cold water:
 ST3 in L= 0
 ST4 in L= 0.125m
 ST5 in L= 0.25m
 ST6 in L= 0.375m
 ST7 in L= 0.5 m
Hot water:
 ST1 in L= 0
 ST2 in L= 0.5m
8. Repeat steps from 1 to 7, changing the flow direction and selecting parallel flow,
as it is indicated in the operation section, keeping constant the hot flow SC-1 or
(C-1) and the cold flow SC-2 or (C-2). Obtain data for parallel flow.
 Parallel flow
Cold water:
 ST3 in L= 0
 ST4 in L= 0.125m
 ST5 in L= 0.25m
 ST6 in L= 0.375m
 ST7 in L= 0.5 m
Hot water:
 ST1 in L= 0
 ST2 in L= 0.5m
7.5.2.4 Worksheet
Student: ________ Year: __________
Type of flow: _____________
Temperature Distance
ST-16 (ºC)
ST-1 (ºC)
ST-2 (ºC)
ST-3 (ºC)
ST-4 (ºC)
ST-5 (ºC)
ST-6 (ºC)
ST-7 (ºC)
Experiment
Student: ________ Year: __________
Conclusions:
1. Analyze the differences obtained between both graphs and explain them.
7.5.3 Practical exercise 3: Calculation of the LMTD for a shell and tube
exchanger
7.5.3.1 Objective
The objective of this practical exercise is to calculate the logarithmic mean

temperature difference (LMTD) of a shell and tube exchanger, knowing the inlet and
outlet temperature values of the fluids of the hot and cold circuits.
7. Repeat steps 3 and 6 keeping constant the flow value SC-1 or (C-1) and the flow
value SC-2 or (C-2) for different water temperatures in the tank ST-16: 50ºC,
55ºC and 60ºC.
8. After recording the values, calculate the LMTD ( Tlm ) according to the
following equation:
T1  T2
Tlm 
 T 
ln  1 
 T2 
Where:
- For countercurrent flow
ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
9. Obtain the value of the LMTD (ΔTlm) for countercurrent flow.
10.Repeat steps from 1 to 9 changing the direction of the working flow to work in
parallel. Obtain the value of the LMTD (ΔTlm) for parallel flow.
- For parallel flow

ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
7.5.3.4 Worksheet
Student: ________________ Year: __________
Type of flow:_____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
ΔT1 (K)
ΔT2 (K)
ΔTlm (K)
Conclusions:
1. Having obtained the values ΔTlm in countercurrent flow and parallel flow, which
differences can you see between both of them? Explain your answer.
7.5.4 Practical exercise 4: Calculation of the overall heat transfer coefficient in a

shell and tube exchanger
7.5.4.1 Objective
The objective of this practical exercise is to calculate the overall heat

transfer coefficient (U) in a shell and tube exchanger, knowing the values of the inlet
and outlet temperatures of the hot and cold fluids.
operation of the exchanger in countercurrent flow configuration, according to
the operation section.
7. Repeat steps 3 and 6 keeping constant the flow value SC-1 or (C-1) and the flow
value SC-2 or (C-2) for different water temperatures in the tank ST-16: 50ºC,
55ºC and 60ºC.
8. After recording the values, calculate the LMTD according to the following
equation:
T1  T2
Tlm 
 T 
ln  1 
 T2 
Where:
 For countercurrent flow

ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
9. Calculate the value of the overall heat transfer coefficient (U) in the inner tube,
for countercurrent flow, with the following equation:
qc = U *A* Tlm
Where:
- U = overall heat transfer coefficient (W/m2.K)
- qc = mc* Cpc *(Tc,e – Tc,s) measured in (J/s=W)
Being:
o mc  mass flow of water in hot circuit (g/s)*

* The water flow is measured by SC-1 or (C-1). Measured flow is

expressed in (l/min), so this value will be converted with water density
(ρwater) to the mean temperature between the value of Tc,e and Tc,s of
the exchanger (ST-1 and ST-2 respectively).
l g 1 min g
mc   ( ) 
min l 60s s
o Cpc  specific heat of water to the mean temperature between the

value of Tc,e and Tc,s of the exchanger (J/g.K).
o Tc,e  inlet temperature of water from the hot circuit to the exchanger,
o Tc,s  outlet temperature of water from the hot circuit to the exchanger,
- A is the total area of the heat exchanger in the inner side of the inner tube
(m2).
A = (π*L*Dinner side of tube) * Nt

o L= length of the inner tube (m).
o Dint tubo = inner diameter of the inner tube (m).

o Nt = number of tubes in the exchanger.
- Tlm is the value calculated in section 8.
10. Repeat steps from 1 to 9 changing the working flow direction to work in parallel.
Obtain the coefficient (U) for parallel flow.
 For parallel flow

ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
7.5.4.4 Worksheet
Student: _______________ Year: __________
Type of flow: _____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
SC-1 or (C-1) (g/s)
ΔT1 (K)
ΔT2 (K)
ΔTlm (K)
A (m2)
Cpc (J/g.K)
qc (J/s = W)
U (W/m2.K)
Student: ________________ Year: __________
Conclusions:
1. After obtaining the value of U, in countercurrent flow and in parallel flow,

compare both values and explain the differences arisen when the flow direction
is changed.
7.5.5 Practical exercise 5: Calculation of the effectiveness of the shell and tube
exchanger with the ε-NTU method
7.5.5.1 Objective
The objective of this practical exercise is to determine the effectiveness of

the exchanger experimentally (according to the NTU method), to estimate the water
outlet temperatures of the hot and cold circuit and to compare them with the values
measured by the temperature sensors.
7. Knowing the water flowrate of the hot circuit (mc), measured by SC-1 or (C-1)
in (l/min) and the water flowrate of the cold circuit (mf), measured by SC-2 or
(C-2) in (l/min), convert the flowrate units from (l/min) to (g/s). To that end
follow this procedure:
mc  l g 1 min
 ( )  
g
min l 60s s
mf  l g 1 min
 ( )  
g
min l 60s s
NOTE: where ρ is the density of the fluids that flow through each circuit, both
the hot and cold circuit. For the hot fluid, density is obtained to the average
temperature between ST-1 and ST-2. For the cold fluid, density is obtained to the
average temperature between ST-3 and ST-7.
8. To calculate the efficiency with the NTU-ε method, employ the chart from
annex 2. For that purpose the NTU value (number of transfer units) and the Cr
value must be known. With these two values the value of the exchanger
efficiency (ε) will be easily obtained.
 Take into account the expression below to calculate the value of NTU:
U*A
NTU =
(m * Cp ) min
 To calculate the overall heat transfer coefficient (U) follow this equation:
qc = U *A *Tlm
Where:
- U = overall heat transfer coefficient (W/m2.K)
- qc = mc * Cpc * (Tc,e – Tc,s)
o qc is the heat flow of the hot fluid and it is measured in (W=J/s)
o mc  mass flow of the hot circuit water (g/s)*
* The water flowrate of the hot circuit is measured by SC-1 or (C-1).

The flowrate measured is expressed in (l/min), so this value will be
converted through the water density (ρwater) to the average
temperature between the value of Tc,e and Tc,s of the exchanger (ST-
1 and ST-2 respectively).
o Cpc is the specific heat of the hot fluid to the average temperature
between the inlet and the outlet of the exchanger (ST-1 and ST-2),
measured in (J/g.K).
o (Tc,e– Tc,s) is the temperature difference between the inlet and outlet
of the hot fluid of the exchanger, measured by ST-1 and ST-2 (K).
- Tlm is the logarithmic mean of the temperatures obtained as follows:
T1  T2
Tlm 
 T 
ln  1 
 T2 
Being, for countercurrent flow:

ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
- A is the total area of heat exchange in the inner side of the inner tube (m2).
A = (π*L*Dinner side of tube) * Nt
o A = total area of heat exchange (m2)
o L= length of the inner tube (m)
o Dinnner side of tube = inner diameter of the inner tube (m)
o Nt = number of tubes in the exchanger
 To calculate the Cmin or (m*Cp)min, follow this procedure:
- Cmin = (m * Cp) of lower value, measured in (J/s.K)
- Cmax = (m * Cp) of higher value, measured in (J/s.K)
Where:
- mc  mass flow of the hot circuit water (g/s)
- mf  mass flow of the cold circuit water (g/s)
- Cpc  specific heat of the hot circuit water (J/g.K)
- Cpf  specific heat of the cold circuit water (J/g.K)
Knowing the mass flow of both fluids (mc and mf) and their corresponding
heat capacity (Cpc and Cpf), the user must analyze which fluid is the Cmin and which
fluid is the Cmax.
The parameter Cr is obtained by relating Cmin and Cmax, which is defined as:
C min
Cr =
C max
 To calculate the efficiency value
Knowing the value of Cr and the value of NTU, calculate the efficiency of
the exchanger (ε) with the chart that relates ε with NTU, included in annex 2.
Efficiency can also be expressed as follows:
Qreal
ε=
Qmax
 To calculate Qmax and Qreal
Obtain Qmax as follows:
Qmax = Cmin * (Tc,e – Tf,e)
Where:
- Qmax = maximum flow of heat in the exchanger (W=J/s)
- Cmin = (m * Cp)min, measured in (J/s.K)
- Tc,e = inlet temperature of the hot circuit water, ST-1 (K)
- Tf,e = inlet temperature of the cold circuit water, ST-7 (K) for
countercurrent flow
Obtain Qreal by solving from the equation:
Qreal
ε=
Qmax
 Obtain the values of Tc,s and Tf,s
With the value of Qreal obtained, calculate the outlet temperatures of the hot
fluid from the exchanger (Tc,s) and the cold fluid from the exchanger (Tf,s), following
the expressions below and solving:
Qreal = mc * Cpc * (Tc,e - Tc,s)
Qreal = mf * Cpf * (Tf,s – Tf,e)
Where:
- Qreal = real heat flow in the exchanger (W=J/s)
- mc  mass flow of water of the hot circuit (g/s)
- mf  mass flow of water of the cold circuit (g/s)
- Cpc  specific heat of water of the hot circuit (J/g.K) at the average
temperature between ST-1 and ST-2
- Cpf  specific heat of water of the cold circuit (J/g.K) at the average
temperature between ST-3 and ST-7
- To calculate the Tc,s and Tf,s, compare it with:
Tc,s = ST-2
Tf,s = ST-3
9. Repeat steps from 1 to 8 changing the flow direction and working in parallel.
- For parallel flow

ΔT1 = (ST-1) – (ST-3)
ΔT2 = (ST-2) – (ST-7)
- To calculate Tc,s and Tf,s, compare it with:
Tc,s = ST-2
Tf,s = ST-7
7.5.5.4 Worksheet
Student: __________________ Year: __________
Type of flow: ______________
Experiment 1
ST-16 (ºC or K )
ST-1 (ºC or K)
ST-2 (ºC or K )
ST-3 (ºC or K)
ST-7 (ºC or K)
SC-1 or (C-1) ( l/min)
SC-1 or (C-1) ( g/s)
SC-2 or (C-2) ( l/min)
SC-2 or (C-2) ( g/s)
Cmin (J/s.K)
Cmax (J/s.K)
Cr (dimensionless)
qc (W=J/s)
A (m2)
ΔTlm (K)
U (W/m2.K)
NTU (dimensionless)
 (dimensionless)
Qmax (W=J/s)
Qreal (W=J/s)
Tc,s (ºC or K )
Tf,s (ºC or K)
Student: __________________ Year: __________
Conclusions:
1. Compare the efficiency in countercurrent and parallel. Explain the results obtained.
2. Analyze the values of the outlet temperatures of the hot and cold fluids obtained by
the NTU- method. Compare them with the values measured by the temperature
sensors (ST-2, ST-3 and ST-7).
7.5.6 Practical exercise 6: Influence of the flow in the heat transfer. Calculation
of Reynolds number in the side of the tubes
7.5.6.1 Objective
The objective of this practical exercise is to study the influence of the hot
circuit water flow in the heat transfer in the exchanger. To calculate the Reynolds
number associated to the motion of water of the hot circuit that flows through the side
of the tubes.
(C-1) between 1 and 2 l/min, as it is indicated in the operation section.
7. Decrease the water flow of the hot circuit SC-1 or (C-1), keeping constant the
water flow of the cold circuit SC-2 or (C-2).
8. When the system is stable, record the temperatures and flows of section 6.
9. Repeat steps from 6 to 8 for the water flows of the hot circuit SC-1 or (C-1).
10.Calculate Reynolds number (NRe) for each flow measured of SC-1 or (C-1),
according to the expression:
Gt  Di
N Re 

Where:
- Di = inner diameter of the inner tube (m)
- µ = viscosity (kg/m.s) at the average temperature of the hot circuit water

between ST-1 and ST-2
- Gt = mass flow of the fluid that flows inside the tubes divided by the
cross-sectional area of all the tubes (kg/s.m2)
Being:
mc
Gt =
at
o mc  mass flow of the hot water circuit (kg/s)*
* The water flow of the hot circuit is measured by SC-1 or (C-

1). Measured flow is expressed in (l/min), so this value will be

converted with water density (ρwater) to the mean temperature
between the value of Tc,e and Tc,s of the exchanger (ST-1 and
ST-2 respectively).
mc  l g 1 min
 ( ) x
1kg

kg
min l 60s 1000 g s
o at = cross-sectional area of the tubes (m2). The cross-sectional area

is calculated as follows:
N t * a't
at = ( )
n
- Nt = number of tubes
- n = number of passes through the tubes, n = 1
- a’t = cross-sectional area of the tube (m2)
a’t = π*ri2 = π*(Di/2)2
Being, Di = inner diameter of the inner tube (m)
11.Repeat steps from 1 to 10 changing the direction of the flow and working in
parallel. Calculate the NRe for parallel flow.
7.5.6.4 Worksheet
Student: ________________ Year: __________
Type of flow: _____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
SC-1 or (C-1) (kg/s)
Di (m)
µ (kg/m.s)
Gt (kg/m2.s)
NRe (dimensionless)
Student: _______________ Year: __________
Conclusions:
1.- Analyze the influence of the hot circuit water flow in the NRe depending on the
flow direction and explain the results obtained.
7.5.7 Practical exercise 7: Influence of the flow in the heat transfer. Calculation of
Reynolds number in the side of the shell
7.5.7.1 Objective
The objective of this practical exercise is to study the influence of the hot
circuit water flow in the heat transfer in the exchanger. To calculate the Reynolds
number associated to the motion of water of the cold circuit that flows through the side
of the shell.
4. Switch on the impeller pump AB-1 and set a flowrate for the cold circuit SC-2
or (C-2) of 2 l/min approx. with VR-2.
5. Set a flowrate for the hot circuit SC-1 or (C-1), until the system stabilizes to a
temperature of 60ºC in ST-16.
7. Decrease the water flow of the cold circuit SC-2 or (C-2) with VR-2 to 1.9
l/min, keeping constant the water flow of the hot circuit SC-1 or (C-1).
8. When the system is stable, record the temperatures and flows of section 6.
9. Repeat steps from 6 to 8 for water flows of the cold circuit SC-2 or (C-2) of 1.7
and 1.5 l/min.
10.Calculate Reynolds number (NRe) for the annular area, for each flow measured,
according to the expression:
Gc * ( Deq )
N Re 

Where:
- Deq = equivalent diameter of the shell for arrangement in square.
 * Do 2
4 * ( PT  (
2
))
Deq= 4
 * Do
 PT = distance from center to center between two tubes (m).
 Do = external diameter of the tubes (m).
- µ = viscosity (kg/m.s) at the average temperature of cold hot circuit

water: (ST3+ST7)/2
- Gc = mass flow of the fluid that flows through the annular side divided by
the heat transfer area in the shell (kg/s.m2)
- Gt = mass flow of the fluid that flows through the annular side divided by
the cross-sectional area of shell (kg/s.m2)
Being:
mf
Gc =
ac
Where:
o mf  mass flow of the cold water circuit (kg/s)*
* The water flow of the cold circuit is measured by SC-2 or (C-

2). Measured flow is expressed in (l/min), so this value will be
between the value of Tf,e and Tf,s of the exchanger (ST-3 and ST-
7 in countercurrent flow, respectively).
mf  l g 1 min
 ( ) x
1kg

kg
min l 60s 1000 g s
o at = cross-sectional area of the shell (m2). The cross-sectional area is

calculated as follows:
Di c * C * B
ac =
Pt
Where:
 Dic = internal diameter of the shell (m)
 C = space between tubes (m)

 PT is the distance from center to center between two tubes (m)
 B is the space between baffles (m)
parallel. The values of the physical properties are the same than for
countercurrent flow, that is to say, the average temperature will be between ST-
3 and ST-7. Calculate the NRe for parallel flow.
7.5.7.4 Worksheet
Student: _______________ Year: __________
Type of flow: _____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
Deq (m)
µ (kg/m.s)
Gc (kg/m2.s)
NRe (dimensionless)
Student: _______________ Year: __________
Conclusions:
1.- Analyze the influence of the hot circuit water flow in the NRe depending on the
flow direction and explain the results obtained.
2.- Compare the results obtained for the inner tube and compare them with the results
obtained for the annular area.
7.5.8 Practical exercise 8: Obtainment of Prandtl number for the tubes side
7.5.8.1 Objective
The objective of this practical exercise is to obtain Prandtl number for the
side of the tubes keeping Reynolds number constant.
4. Switch on the impeller pump AB-1 and set a water flowrate for the hot circuit
SC-1 or (C-1) according to the operation section.
5. Set a water flowrate for the cold circuit SC-2 or (C-2), until the system stabilizes
to a temperature of 45ºC in ST-16.
7. Increase the temperature of the heating tank ST-16 to 50ºC, keeping constant the
water flow of the hot circuit SC-1 or (C-1).
8. When the system is stable record the temperatures and flows from step 6.
9. Repeat steps from 3 to 8 for temperature values of ST-16 of 55ºC and 60ºC.
10.For each value of ST-16, calculate Prandtl number for each experiment
according to the equation below:
Cp * 
N Pr 
kf
Where:
- Cp = specific heat of the hot circuit water to the mean temperature

between ST-1 and ST-2 (kJ/kg.K).
- µ = viscosity of the hot circuit water to the mean temperature between

ST-1 and ST-2 (kg/m.s).
- kf = thermal conductivity of the hot circuit water to the mean temperature

between ST-1 and ST-2 (W/m.K).
NOTE: take into account that W=J/s and the Cp is measured in (kJ/kg.K), so that
it should be converted as follows:
Cp *  1000 J
N Pr  .( )
kf 1kJ
11. Repeat steps from 1 to 10 changing the direction of the flow and working in
countercurrent flow, that is to say, the mean temperature will be between ST-1
and ST-2. Calculate the NPr for parallel flow.
7.5.8.4 Worksheet
Student: _________________ Year: __________
Type of flow: _____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
Tmean (ºC or K)
Cp (kJ/kg.K)
µ (kg/m.s)
kf (W/m.K) = (J/s.m.K)
NPr (dimensionless)
Student: ________________ Year: __________
Conclusions:
1.- Analyze the influence of the temperature of the heating tank in the NPr depending
on the flow direction. Explain the results obtained.
7.5.9 Practical exercise 9: Obtainment of Prandtl number for the shell side
7.5.9.1 Objective
The objective of this practical exercise is to obtain Prandtl number for the
side of the shell keeping Reynolds number constant.
5. Set a water flowrate for the hot circuit SC-1 or (C-1), according to the operation,
until the system stabilizes to a temperature of 45ºC in ST-16.
Cp * 
N Pr 
kf
Where:
- Cp = specific heat of the cold circuit water to the mean temperature

- µ = viscosity of the cold circuit water to the mean temperature between

- kf = thermal conductivity of the cold circuit water to the mean

temperature between ST-3 and ST-7 (W/m.K).
Cp *  1000 J
N Pr  .( )
kf 1kJ
and ST-7. Calculate the NPr for parallel flow.
7.5.9.4 Worksheet
Student: ________________ Year: __________
Type of flow: ___________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
Tmean (ºC or K)
Cp (kJ/kg.K)
µ (kg/m.s)
kf (W/m.K) = (J/s.m.K)
NPr (dimensionless)
Student: ________________ Year: __________
Conclusions:
1.- Analyze the influence of the increment of the of the heating tank temperature in the
NPr depending on the direction of the flow. Explain the results obtained.
2.- Compare the results obtained for the inner tube and compare them with the results
obtained for the annular area.
7.5.10 Practical exercise 10: Obtainment of Nusselt number and the heat transfer
coefficient by convection (hi) for the side of the tubes
7.5.10.1 Objective
The objective of this practical exercise is to obtain Prandtl number, Reynolds

number and Nusselt number and to calculate the heat transfer coefficient by convection
(hi) for the side of the tubes.
water flow of the hot circuit SC-1 or (C-1).
Cp * 
N Pr 
kf
Where:
- Cp = specific heat of the hot circuit water to the mean temperature

- µ = viscosity of the hot circuit water to the mean temperature between

- kf = thermal conductivity of the hot circuit water to the mean temperature

between ST-1 and ST-2 (W/m.K).
Cp *  1000 J
N Pr  .( )
kf 1kJ
11.When the value of ST-16 is 60ºC, perform several experiments with different
water flowrates of the hot circuit SC-1 or (C-1).
12.Obtain Reynolds number (NRe) according to the equation:
Gt * Di
N Re 

Where:
- Di = inner diameter of the inner tube (m)
- µ = viscosity (kg/m.s) to the mean temperature of water in the hot circuit:

(ST1+ST2)/2
- Gt = mass flow of the fluid that flows through the inner tube divided by
the cross-sectional area of the inner tube (kg/s.m2)
Being:
mc
Gt =
at
o mc  mass flow of water in the hot circuit (kg/s)*
* The water flow of the hot circuit is measured by SC-1 or (C-1).

Measured flow is expressed in (l/min), so this value will be
between the value of Tc,e and Tc,s of the exchanger (ST-1 and ST-2
respectively).
mc  l g 1 min
 ( ) x
1kg

kg
min l 60s 1000 g s
o at = cross-sectional area of the tubes (m2). The cross-sectional area

is calculated as follows:
N t * a't
at= ( )
n
- Nt = number of tubes
- n = number of passes through the tubes, n = 1
- a’t = area of the cross-section of the tube (m2)
a’t = π*ri2 = π*(Di/2)2
Being, Di the inner diameter of the inner tube (m).
13.Obtain the coefficient of convection for the side of the tubes (h i), following the
equation below:
 For laminar flow condition:
NNu = 1.86. [NRe*NPr*(d/L)]1/3 * (μ/ μw)0.14
When [NRe*NPr*(d/L)] >10.
 For turbulent flow condition:
NNu = 0.023. (NRe)0.8 * (NPr)n
Being:
- NRe = Reynolds number obtained in step 12
- NPr = Prandtl number obtained in step 10

- (µ/µw)0.14 = 1, if there is water or a low viscosity liquid flowing through
the exchanger. This coefficient is the relation between the dynamic
viscosity of the fluid (µ), measured in (kg/m.s) and the dynamic viscosity
of the fluid (µw) in the tube wall or shell, measured in (kg/m.s)
- d = Di = internal diameter of the inner tube (m)
- L = length of the inner tube (m)
14.Calculate the value of the heat transfer coefficient by convection (hi), following
the equation below:
N Nu  k f
hi 
Di
Where:
- hi = heat transfer coefficient by convection through the inner tube

(W/m2.K)
- NNu = Nusselt number obtained in step 13
- kf = thermal conductivity of water (W/m.K) to the mean temperature of

water in the hot circuit between ST-1 and ST-5.
- Di = inner diameter of the inner tube (m).
15.Repeat steps from 1 to 14 changing the flow direction to work in parallel. The
values of the physical properties are the same than for countercurrent flow, that
is to say, the mean temperature will be between ST-1 and ST-2. Calculate the
coefficient (hi) for parallel flow.
7.5.10.4 Worksheet
Student: ________________ Year: __________
Type of flow: ___________
ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
Mean temperature (ºC
or K)
µ (kg/m.s)
Cpc (kJ/kg.K)
kf (W/m.K)
NPr (dimensionless)
ST-16 (ºC or K )
Gi (kg/m2.s)
µ (kg/m.s)
Di (m)
NRe (dimensionless)
NNu (dimensionless)
hi (W/m2.K)
Student: __________________ Year: __________
Conclusions:
1.- Compare the results obtained for both flow directions. Does the flow direction
influence the transfer coefficient by convection (hi)?
7.5.11 Practical exercise 11: Obtainment of Nusselt number and the heat transfer
coefficient by convection (ho) for the side of the shell
7.5.11.1 Objective
The objective of this practical exercise is to obtain Prandtl number, Reynolds

number and Nusselt number and to calculate the heat transfer coefficient by convection
(ho) for the side of the shell.
4. Switch on the impeller pump AB-1 and set a water flowrate for the cold circuit
Cp * 
N Pr 
kf
Where:
- Cp = specific heat of the cold circuit water to the mean temperature

- µ = viscosity of the cold circuit water to the mean temperature between

- kf = thermal conductivity of the cold circuit water to the mean

temperature between ST-3 and ST-7 (W/m.K).
Cp *  1000 J
N Pr  .( )
kf 1kJ
11.When the value of ST-16 is 60ºC, perform several experiments with different
water flowrates of the cold circuit SC-2 or (C-2).
12.Obtain Reynolds number (NRe) according to the equation:
Gc * Deq
N Re 

Where:
- µ = viscosity (kg/m.s) to the mean temperature of water in the cold

circuit: (ST-3+ST-7)/2
- Deq = equivalent diameter of the shell for arrangement in square.
Where:
 * Do 2
4 * ( PT  (
2
))
Deq= 4
 * Do
 PT = distance from center to center between two tubes (m)
 Do = external diameter of the tubes (m)
- Gc = mass flow of the fluid that flows through the shell side divided by the
cross-sectional area of the shell (kg/s.m2)
Being:
mf
Go =
ac
o mf  water mass flow of the cold circuit (kg/s)*
* The water flow of the cold circuit is measured by SC-2 or (C-2).

Measured flow is expressed in (l/min), so this value will be

between the value of Tc,e and Tc,s of the exchanger (ST-3 and ST-7
respectively).
mf  l g 1 min
 ( ) x
1kg

kg
min l 60s 1000 g s
o ac = cross-sectional area of the shell (m2). The cross-sectional area is

calculated as follows:
Di c * C * B
ac =
PT
Where:
 Dic = inner diameter of the shell (m)
 C = space between tubes (m)
 PT is the distance from center to center between two tubes (m)
 B is the space between baffles (m).
13.Obtain the value of the heat transfer coefficient by convection for the side of the
shell following the correlation below:
 NNu = 0.36*(NRe)0.55*(NPr)0,3
Being:
- NNu = Nusselt number (dimensionless)
- NRe = Reynolds number obtained in step 12

- NPr = Prandtl number obtained in step 10
14.Calculate the value of the heat transfer coefficient by convection (hi) following
the equation below:
N Nu  k f
ho 
Deq
Where:
- ho = heat transfer coefficient by convection in the side of the shell

(W/m2.K)
- NNu = Nusselt number (dimensionless) obtained in step 13
- kf = thermal conductivity of water (W/m.K) to the mean temperature of

water in the cold circuit between ST-3 and ST-7.
- Deq = equivalent diameter of the shell (m).
Where:
 * Do 2
4 * ( PT  (
2
))
Deq= 4
 * Do
 PT = distance from center to center between two tubs (m)
 Do = external diameter of the tubes (m)

15.Repeat sections from 1 to 14 changing the working flow direction to work in

and ST-7. Calculate the value of the coefficient (ho) for parallel flow.
7.5.11.4 Worksheet
Student: _________________ Year: __________
Type of flow: ____________

ST-16 (ºC or K)
ST-1 (ºC or K)
ST-2 (ºC or K)
ST-3 (ºC or K)
ST-7 (ºC or K)
Mean temperature (ºC
or K)
µ (kg/m.s)
Cpc (kJ/kg.K)
kf (W/m.K)
NPr (dimensionless)
ST-16 (ºC or K)
Go (kg/m2.s)
µ (kg/m.s)
Deq (m)
NRe (dimensionless)
NNu (dimensionless)
ho (W/m2.K)
Student: _________________ Year: __________
Conclusions
1.- Compare the results obtained for both flow directions. Does the flow direction
influence the transfer coefficient by convection (ho)? Are there differences between the
coefficients hi and ho? Explain the answer.
7.6 ANNEXES
7.6.1 Annex I: Water table properties

7.6.2 Annex II: Plots
7.6.2.1 ε-NTU plots
ε-NTU plots for parallel flow (left) and countercurrent flow (right)

EXP2,3,4-Shell and Tube Full

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PRACTICAL EXERCISES MANUAL

Unit ref.: TICT Date: February 2016 Pg: 1 / 108

7 PRACTICAL EXERCISES MANUAL.............................................................................................2

Unit ref.: TICT Date: February 2016 Pg: 2 / 108

7 PRACTICAL EXERCISES MANUAL

Unit ref.: TICT Date: February 2016 Pg: 3 / 108

7.1.2 Description of the unit

7.1.2.1 Base unit

Unit ref.: TICT Date: February 2016 Pg: 4 / 108

- Heating element, AR-1.

- Level sensor, AN-1, to guarantee a specific level in the tank.

- Temperature sensor, ST-16, of the water in the tank.

Unit ref.: TICT Date: February 2016 Pg: 5 / 108

5. VR-2: regulation valve of the water flowrate of the cold circuit.

6. VR-3: regulation valve of the water flowrate of the hot circuit.

 Particularities of the TIUSB unit:

Unit ref.: TICT Date: February 2016 Pg: 6 / 108

7.1.2.2 TICT, shell and tube heat exchanger

Unit ref.: TICT Date: February 2016 Pg: 7 / 108

- ST-4: temperature sensor of the water in the cold circuit at an intermediate

- ST-5: temperature sensor of the water in the cold circuit at an intermediate

- ST-6: temperature sensor of the water in the cold circuit at an intermediate

Unit ref.: TICT Date: February 2016 Pg: 8 / 108

7.1.3 Description of the process

7.1.3.1 Base unit

Unit ref.: TICT Date: February 2016 Pg: 9 / 108

The base unit TIUS (TIUSB) fulfills the following functions:

2. Measurement of the hot water flow.

3. Measurement of the cold water flow.

Unit ref.: TICT Date: February 2016 Pg: 10 / 108

4. Pumping of the hot water.

7.1.3.2 TICT: Shell and tube heat exchanger

Unit ref.: TICT Date: February 2016 Pg: 11 / 108

7.1.3.3 TICT in countercurrent flow

Hot water circuit

Unit ref.: TICT Date: February 2016 Pg: 12 / 108

Cold water circuit

Unit ref.: TICT Date: February 2016 Pg: 13 / 108

7.1.3.4 TICT in parallel flow

7.1.4 Practical possibilities

Unit ref.: TICT Date: February 2016 Pg: 14 / 108

- Overall energy balance in the exchanger and study of heat losses in

- Obtainment and representation of the temperature distribution in a shell and

- Calculation of the logarithmic mean of the temperatures for parallel flow.

- Calculation of the logarithmic mean of the temperatures for countercurrent

- Calculation of the overall heat transfer coefficient (U) for countercurrent

- Determination of the effectiveness of the exchanger. ε-NTU method for

- Determination of the effectiveness of the exchanger. ε-NTU method for

Unit ref.: TICT Date: February 2016 Pg: 15 / 108

7.1.5 General specifications

7.1.5.1 Base unit

- Tank made of stainless steel (30 l.) equipped with:

o Electric heating element AR-1. Power: 3000 W.

o Level switch AN-1.

o Temperature sensor ST-16.

o Drain valve to drain the water from the heating tank.

Unit ref.: TICT Date: February 2016 Pg: 16 / 108

on the exchanger coupled to the base unit due to pressure drops).

- Pressure regulation valve RP-1.

 Particular specifications for the TIUS unit