Double Pipe / Concentric Tube / U-bend / Hair-pin HE:

Sr # Heat Transfer Area Reference

1 100 − 150𝑓𝑡 2 McCabe, 7th Ed, Page:327

2 10 − 15𝑚2 105 − 160𝑓𝑡 2 HT in Process Eng. by Cao, Page:98

3 100 − 200𝑓𝑡 2 Kern, Page: 103

4 2 − 50𝑚2 20 − 540𝑓𝑡 2 Chemical Process Engineering by Harry Silla, Page: 151

Heat Exchangers by Kakac & Liu, 3rd Ed; CRC Press,

5 50𝑚2
USA, 2012, Page: 273.
0.5 − 20𝑚2 5 − 215𝑓𝑡 2 for DPHE
6 Plant Design by Peters, 5th Ed, Page: 677, Table: 14.1
10 − 200𝑚2 110 − 2150𝑓𝑡 2 for Multiple-Pipe

Up to 1000 𝑓𝑡 2 for finned DP in series

7 PHT by Serth, 2nd Ed; Page: 68
1000 − 12000𝑓𝑡 2 for finned multiple-pipe in series
Key / Characteristic Features:
1. PD by Peters et al, Ed: 5th, Table: 14-6, Page: 677.
0.25 < 𝐴𝐷𝑃 < 20 𝑚2 , 10 < 𝐴𝑀𝑃 < 200 𝑚2
𝑃𝑎 ≤ 30𝑀𝑃𝑎 , 𝑃𝑖𝑝 ≤ 140 𝑀𝑃𝑎
−100 ≤ 𝑇 ≤ 600℃
𝑚 𝑚
2 ≤ 𝑈𝐿 ≤ 3 , 10 ≤ 𝑈𝐺 ≤ 20
𝑠 𝑠
2. Heat Exchangers by Kakac & Liu, 3rd Ed; CRC Press, USA,
2012, Page: 273-275.
𝐴 ≤ 50 𝑚2
2 ≤ 𝐷𝑖 ≤ 8 𝑖𝑛 , 0.75 ≤ 𝑑𝑜 ≤ 4 𝑖𝑛
1.5 ≤ 𝐿𝐻𝑃 ≤ 12 𝑚 ⟹ 0.75 ≤ ∆𝐿 ≤ 6 𝑚
3. HT in Process Eng. By Cao, McGraw-Hill, USA, 2010, Table: 5.1, Page: 98.
Inner Pipe Outer Pipe
0.75,1,1.25 2
NPS (in) 0.75,1,1.25 2.5
0.75,1,1.25,1.5,2 3
0.75,1,1.25,1.5,2,3 4

4. Serth’s PHT, 2nd Ed; Elsevier, USA, 2014, Page: 68.

For Double Pipe Heat Exchanger
0.75 ≤ 𝑁𝑃𝑆𝑖 ≤ 6 𝑖𝑛
2 ≤ 𝑁𝑃𝑆𝑜 ≤ 8 𝑖𝑛
For Multi-tube Exchangers
3 ≤ 𝑁𝑃𝑆𝑜 ≤ 16 𝑎𝑛𝑑 𝑒𝑣𝑒𝑛 36 𝑖𝑛
 Darcy Friction Factor
Flow Regime
Inner Pipe Annulus
64 96
𝑓𝐷 = 𝑓 𝑘 ∗ ≈
𝑁𝑅𝑒 𝑁𝑅𝑒
64 𝑑𝑜
𝑓𝐷 = 𝑘=
Laminar / Streamline Flow 𝑁𝑅𝑒 𝐷𝑖
1−𝑘 2
𝑓 𝑘 = ≈ 1.5
1 + 𝑘 2 + 1 − 𝑘 2 / ln 𝑘

Serth’s PHT, 2nd Ed; Page: 102

−0.2314
Turbulent Flow 𝑓𝐷 = 0.3673𝑁𝑅𝑒 …Serth,2nd Ed; Page:102
−0.42
𝑁𝑅𝑒 > 3000 𝑓𝐷 = 0.014 + 1.056𝑁𝑅𝑒 …Kern, Page:53
Transition / Buffer Flow
as well as 𝑓𝐷 = 5.5 ∗ 10−3 1 + 2 ∗ 104 𝜀 + 50/𝑅𝑒 1/3

Turbulent Flow
Also See Heat Exchangers by Kakac & Liu, 3rdEd; Table: 3.4, Page: 102
Pipes are rougher than tubes. Therefore 𝑓𝑝𝑖𝑝𝑒 > 𝑓𝑡𝑢𝑏𝑒 for same Re.
Determination of Energy Losses:
Darcy’s / Modified Darcy’s law shows that head lost due to skin / form friction is equal to the
product of friction parameter 𝑲𝒇 / loss coefficient 𝑲𝑳 and kinetic (or velocity) head ℎ𝐾 . Therefore,
ℎ𝑠𝑓 = 𝐾𝑓 ∗ ℎ𝐾 , ℎ𝑓𝑓 = 𝐾𝐿 ∗ ℎ𝐾 , ℎ𝑓 = ℎ𝑠𝑓 + ℎ𝑓𝑓
Pressure drop ∆𝑃 is product of specific weight 𝛾 and head lost ℎ𝑓 due to friction.
∆𝑃𝑠𝑓 = 𝛾 ∗ ℎ𝑠𝑓 , ∆𝑃𝑓𝑓 = 𝛾 ∗ ℎ𝑓𝑓 , ∆𝑃 = ∆𝑃𝑠𝑓 + ∆𝑃𝑓𝑓
Under isothermal conditions, Darcy’s law is applicable for straight flow channels of
uniform bore.
Head is energy per unit weight of fluid.
𝐿 𝑈2
𝐾𝑓 = 𝑓𝐷 ∗ , ℎ𝐾 =
𝐷 2𝑔
For non-circular or multi-connected channels, equivalent diameter is used as
characteristic size.
Effect of non-isothermal conditions is expressed in terms of viscosity number.
Darcy friction factor under isothermal conditions = 𝑓𝐷
Darcy friction factor under non-isothermal conditions = 𝑓𝐷′
𝑓𝐷′ 𝑓𝐷′ 𝐿
𝑓𝐷 = 𝑛 ⟹ 𝑓𝐷 = 𝑛 ∗ ∗ ℎ𝐾
𝜙 𝜙 𝐷𝑒
𝐴𝑓
Equivalent diameter for non-circular x-section 𝐷𝑒 = = 4𝑟𝐻
𝑊𝑃
𝜇𝑐
Viscosity number 𝜙 =
𝜇𝑤
Absolute or dynamic viscosity at caloric temperature = 𝜇𝑐
Absolute or dynamic viscosity at wall temperature = 𝜇𝑤
Exponent n is dependent on flow regime. Flow Regime Exponent n
Turbulent Flow 0.14
Laminar / Streamline Flow 0.25
Ref: Serth’s PHT, 2nd Ed; Page: 102.
 Loss Coefficient
𝑲𝑳 = 𝒌 𝟏 + 𝒌 𝟐 + 𝒌 𝟑
Flow Regime Flow Channel ′
𝑘13 & 𝑘13 𝑘2′ & 𝑘2
(coefficients based on end effects) (coefficient based on flow-reversal)
𝑘13 = 0 due to inline process piping.
𝑁𝑏𝑒𝑛𝑑 = 2𝑁𝐻𝑃 − 1 ⟹ 𝑁𝑏𝑒𝑛𝑑 ≥ 𝑁𝐻𝑃
Inner Pipe (obvious from Fig: 4.1, Serth, 2nd Ed, Page: 103)
NB: For multiple-tube HE,
′
𝑘13 = 1 ⟹ 𝑘13 = 𝑁𝐻𝑃 𝑘2′ = 1.2 for long-radius 180° bend
⟹ 𝑘2 = 1.2 2𝑁𝐻𝑃 − 1
𝑁𝑖𝑛𝑙𝑒𝑡 = 𝑁𝑜𝑢𝑡𝑙𝑒𝑡 = 𝑁𝐻𝑃
Turbulent 𝑘1′ = 1 & 𝑘3′ = 0.5 NB: Kern and Kraus used
𝑅𝑒 > 3000 ⟹ 𝑘13′
= 1.5 𝑘2′ = 1 ⟹ 𝑘2 = 2𝑁𝐻𝑃 − 1
∴ 𝑘13 = 1.5𝑁𝐻𝑃 However, Kern used
Annulus
𝑘2′ = 0 ⟹ 𝑘2 = 0
NB: Kern assumed
′
𝑘13 = 1 𝑖𝑓 𝑈 ≥ 3𝑓𝑡/𝑠 ⟹ 𝑘13 = 𝑁𝐻𝑃 𝑁𝐻𝑃 = Number of hair-pins in series
′
𝑘13 = 0 𝑖𝑓 𝑈 < 3𝑓𝑡/𝑠 ⟹ 𝑘13 = 0
𝑘13 = 0
Inner Pipe
NB: For multiple-tube HE 𝑘2′ = 1.5; 500 < 𝑅𝑒 < 2100
Laminar 𝑘13 = 𝑓 𝑅𝑒 ⟹ 𝑘2 = 1.5 2𝑁𝐻𝑃 − 1
′
𝑘13 = 3; 𝑅𝑒 > 100
Annulus
⟹ 𝑘13 = 3𝑁𝐻𝑃
NB: For inner pipe, loss coefficient based on end effects is independent of flow regime.
For a specific flow regime, loss coefficient based on flow-reversal is independent of flow channel.

Ref: Serth’s PHT, 2nd Ed; Page: 102-103.

 Effective Surface Roughness 𝜺
Material of Construction
ft mm

Cast Iron 0.00085 0.25

Commercial Steel 0.00015 0.046

Galvanized Iron 0.0005 0.15

Drawn Tubing 0.000005 0.0015

Kern’s Approximation for Turbulent Flow

Flow Channel Loss Coefficient Reason / Condition
1. Nozzle is of same (smaller) diameter as (inner) pipe. Therefore, flow is
NB: inline to axis of pipe.
Inner Pipe 𝑘𝐿 = 0 These facts show 2. Hydraulically smooth (seamless smaller-diameter) pipe.
the importance of 3. Long radius 180° bend (which is 2 to 3 times the diameter of pipe)
U-turn.
𝐾𝐿 = 0 Low fluid velocity 𝑈 < 3 𝑓𝑡/𝑠
Annulus
𝑘𝐿′ = 1 ⟹ 𝑘𝐿 = 𝑁𝐻𝑃 Fluid velocity is sufficiently high (exceeding 3 ft/s).
 Empirical Correlation for Film Coefficient
Flow Regime Constraints
inside tube, pipe or annulus
Seider-Tate Equation 𝑅𝑒 < 2100
0.5 < 𝑃𝑟 < 17000
𝑅𝑒𝑃𝑟 1/3 𝑅𝑒𝑃𝑟 1/3 0.14
𝑁𝑢 = 1.86 𝜙 0.14 𝜙 >2
𝑥 𝑥
Laminar Flow 𝐸 = ±20% to ±40%
1
Ref: Serth’s PHT, 2nd Ed; Page: 101. 𝑅𝑒𝑃𝑟 3 0.14
𝑁𝑢 = 3.66 ∀ 𝜙 < 2 which corresponds to
𝑥
ℎ𝐷 𝜇𝐶𝑝 𝜌𝐷𝑈 𝜇𝑐 𝐿 laminar flow in an infinitely long pipe with constant wall
[𝑁𝑢 = , 𝑃𝑟 = , 𝑅𝑒 = ,𝜙 = ,𝑥 = ]
𝑘 𝑘 𝜇 𝜇𝑤 𝐷 temperature.
𝑅𝑒 > 10000
Seider-Tate Equation 0.5 < 𝑃𝑟 < 17000
10 < 𝑥 < 60
Turbulent Flow 𝑁𝑢 = 0.023𝑅𝑒 0.8 𝑃𝑟1/3 𝜙 0.14 1 + 𝑥 −2/3 𝐸 = ±20
Holds good for gases, low viscosity liquids such as
Ref: Serth’s PHT, 2nd Ed; Page: 101. water, organic solvents and light hydrocarbons when
0.5 < 𝑃𝑟 < 100
Gnielinski Equation

Transition as well as 𝑓𝐷 /8 𝑅𝑒 − 1000 𝑃𝑟 2100 < 𝑅𝑒 < 106

𝑁𝑢 = 1 + 𝑥 −2/3
Turbulent Flow 1 + 12.7 𝑓𝐷 /8 𝑃𝑟 2/3 − 1 0.6 < 𝑃𝑟 < 2000
𝑓𝐷 = 0.782 ln 𝑅𝑒 − 1.51 −2 … CBWE 𝐸 = ±20%

Ref: Serth’ PHT, 2nd Ed; Page: 40.

Also See Heat Exchangers by Kakac & Liu, 3rd Ed; Table: 3.1, 3.3, 3.6, 3.7, Page: 94, 96, 108, 109-110.
Film coefficient for water (inside tube or pipe):
1. HT in Process Eng. By Cao, McGraw-Hill, USA, 2010, Page: 96.
ℎ𝑖 = 1423 1 + 0.0146𝑇𝐴𝑀 𝑈 0.8 /𝑑𝑖0.2
𝑊 𝑚
ℎ𝑖 ≡ 2 , 𝑇𝐴𝑀 ≡ ℃ , 𝑈 ≡ , 𝑑𝑖 ≡ 𝑚
𝑚 𝐾 𝑠
2. Chem. Eng. By Coulson & Richardson, Vol: 1, Ed: 6th, Page: 521.
ℎ𝑖 = 4280 1 + 0.00488𝑇𝐴𝑀 𝑈 0.8 /𝑑𝑖0.2
𝑊 𝑚
ℎ𝑖 ≡ 2 , 𝑇𝐴𝑀 ≡ 𝐾 , 𝑈 ≡ , 𝑑𝑖 ≡ 𝑚
𝑚 𝐾 𝑠
3. PHT by Kern, Fig: 25, Page: 835
ℎ𝑖 = 𝑓 𝑈 ቚ𝑑𝑜 =0.75 𝑖𝑛 ∗ 𝐶 𝑑𝑖
𝑇 ℉
𝐵𝑡𝑢 𝑓𝑡
ℎ𝑖 ≡ 2
, 𝑈 ≡ , 𝑑𝑖 ≡ 𝑖𝑛 , 𝑑𝑜 ≡ 𝑖𝑛 , 𝑇 ≡ ℉
ℎ𝑟𝑓𝑡 ℉ 𝑠
Kern, Fig: 25, Page: 835
 Operation
Heat Transfer for Film Coefficient Momentum Transfer for Pressure Drop
Flow Channel Flow Area
(Thermal Design) (Hydraulic Design)
𝑊𝑃 𝑟𝐻 𝐷𝑒 𝑊𝑃 𝑟𝐻 𝐷𝑒

Circular Pipe or Tube 𝜋 2 𝑑𝑖 𝑑𝑖

𝑑 𝜋𝑑𝑖 𝑑𝑖 𝜋𝑑𝑖 𝑑𝑖
(Cylinder) 4 𝑖 4 4
𝑎𝑏 2𝑎𝑏 𝑎𝑏 2𝑎𝑏
Rectangular Duct 𝑎𝑏 2 𝑎+𝑏 2 𝑎+𝑏 = 𝐷𝐻𝑀
2 𝑎+𝑏 𝑎+𝑏 2 𝑎+𝑏 𝑎+𝑏

𝜋 2 𝐷𝑖2 − 𝑑𝑜2 𝐷𝑖2 − 𝑑𝑜2 𝐷𝑖 − 𝑑𝑜

Circular Annulus 𝐷𝑖 − 𝑑𝑜2 𝜋𝑑𝑜 𝜋 𝐷𝑖 + 𝑑𝑜 𝐷𝑖 − 𝑑𝑜
4 4𝑑𝑜 𝑑𝑜 4

Unlike tube or pipe, WP, HR and ED of annulus depend on transfer operation. (Kern’s approach)

𝑊𝑃𝑃𝐷 𝑟𝐻 𝐻𝑇 𝐷𝑒 𝐻𝑇 𝐷𝑖
For circular annulus = = = 1+ >2
𝑊𝑃𝐻𝑇 𝑟𝐻 𝑃𝐷 𝐷𝑒 𝑃𝐷 𝑑𝑜

𝐷𝑒 = 𝐷𝑐 ቚ = 4𝑟𝐻
𝑟𝐻,○ =𝑟𝐻

𝐴𝑓
𝑟𝐻 =
𝑊𝑃