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NUMERICAL ANALYSIS OF HEAT TRANSFER IN HELICALLY GROOVED TUBES

Thesis · June 2020

DOI: 10.13140/RG.2.2.18201.70241

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 NUMERICAL ANALYSIS OF HEAT
TRANSFER IN HELICALLY GROOVED
TUBES

A Report Submitted in
Partial Fulfilment of the Requirement for the Degree of
Master of Technology
In
Thermal Engineering
By

Voddepalli Soumith
(Scholar No.:- 18-22-113)

Under the supervision of

Dr. Sujit Nath
&
Dr. A. Biswas

Department of Mechanical Engineering

NATIONAL INSTITUTE OF TECHNOLOGY, SILCHAR
 DECLARATION

Thesis Title: Numerical analysis of Heat transfer in helically grooved tubes

Degree for which the Thesis is submitted: Master of Technology

I declare that the presented thesis represents largely my own ideas and work in my own words.
Where others ideas or words have been included, I have adequately cited and listed in the
reference materials. The thesis has been prepared without resorting to plagiarism. I have
adhered to all principles of academic honesty and integrity. No falsified or fabricated data have
been presented in the thesis. I understand that any violation of the above will cause for
disciplinary action by the Institute, including revoking the conferred degree, if conferred, and
can also evoke penal action from the sources which have not been properly cited or from whom
proper permission has not been taken.

Name of the Student: Voddepalli Soumith

Registration No.: 18-22-113

Date:
 CERTIFICATE

It is certified that the work contained in this thesis entitled ‘Numerical analysis of Heat
transfer in helically grooved tubes’ submitted by Voddepalli Soumith, Registration no. 18-
22-113 for the award of M.Tech. is absolutely based on his own work carried out under our
supervision and that this thesis has not been submitted elsewhere for any degree/diploma.

Dr. Sujit Nath Dr. A. Biswas

Mechanical Department Mechanical Department

NIT Silchar NIT Silchar

Date :
 ABSTRACT
Heat transfer enhancement play a prominent role in the energy sector, as the demand for energy
has risen sharply, and there is a concerted effort for cost reductions as well. Various energy
sector industries like thermal power plants, nuclear power plants, food processing industries,
etc.. which require effective utilization of heat are facing problems in proper utilization,
conservation and recovery of heat. Different techniques for heat transfer enhancement are
employed to decrease size, costs and increase the efficiency of heat transfer equipment. Of
these techniques, the helical groove technology is applied in the present study. In this study,
heat transfer enhancement is done by using helical grooves inside the receiver pipe of a
Parabolic Trough Collector. A Numerical analysis was done by varying helix angle, groove
width, depth and no.of grooves and their heat transfer performance were calculated using
Nusselt number and resistance coefficient. The research results indicate that the friction factor
and Nusselt number both increase with the increase of the number of fins, widths and depth
and decrease with helical angle. Among which the helix angle has the most considerable impact
on the heat transfer enhancement and depth of fins being the lowest. Thermal performance
factor was highest for a helix angle 40° and pipe with six grooves inside the pipe.

i
 Table of Contents
Abstract i
Table of Contents ii
List of figures v
List of Tables vi

INTRODUCTION 1
1.1 Overview 1
1.2 Different methods for heat transfer enhancement 2
1.2.1 Active Techniques 2
1.2.2 Passive Techniques 3
1.2.3 Compound Techniques 3
1.3 Thermal Performance Enhancement Techniques 3
1.3.1 Treated surfaces 3
1.3.1.1 Boiling 3
1.3.1.2 Condensation 3
1.3.2 Rough surfaces 4
1.3.3 Extended surfaces 4
1.3.4 Grooves inside pipe 5
1.3.5 Twisted pipe 5
1.3.6 Pipe Inserts 6
1.3.7 Wire coil inserts 6
1.3.8 Rib and groove 6
1.3.9 Coiled tube 7
1.4 Organization of thesis 8
References 9

LITERATURE REVIEW 10
2.1 Overview 10
2.2 Helical grooves in turbulent flow 11
2.3 Objectives of present work 13
References 14

BASICS OF COMPUTATIONAL FLUID DYNAMICS 15

3.1 Overview 15
3.2 Introduction to CFD 15
3.3 Advantages of CFD 16
3.4 Applications of CFD 16
3.5 Basic Approach to use CFD 17
3.5.1 Pre-processing 17
3.5.2 Solving the Problem 17
3.5.3 Post-processing 18
3.6 Discretization Methods in CFD 18

ii
 3.6.1 Finite difference method (FDM) 18
3.6.2 Finite element method (FEM) 19
3.6.3 Finite volume method 19
3.7 Governing equations of Fluid Dynamics 19
3.7.1 Continuity equation 19
3.7.2 Momentum equation 19
3.7.3 Energy equation 19
3.8 Turbulence models 20
3.8.1 Zero equation model 20
3.8.2 One equation model 20
3.8.3 Two equation model 20
3.8.4 Seven equation model 20
3.8.5 Direct Numerical simulation 20
3.8.6 Large eddy simulations 21
3.9 Two equation models 21
3.9.1 Standard k - ε model 21
3.9.2 Realizable k-ε model 21
3.9.3 RNG k – ε model 21
3.9.4 k- ω SST model 22
3.9.5 Standard k- ω model 22
3.14 Implicit and Explicit scheme 22
3.14.1 Explicit scheme 23
3.14.2 Implicit scheme 23
References 24

MATERIALS & METHODOLGY 25

4.1 Validation of present project 25
4.2 Design and Methodology 26
4.2.1 Physical design of grooved pipe 26
4.2.2 Methodology 29
4.2.3 Assumptions 30

NUMERICAL ANALYSIS 31
5.1 Overview 31
5.2 Grid generation 31
5.3 Grid Independence test 32
5.4 Boundary Conditions 33
5.5 Computational Physics 33
5.6 Verification of the Numerical Procedure 34
5.7 Results 35
5.7.1 Effect of Fin Number 36
5.7.3 Effect of groove width 37
5.7.4 Effect of groove depth 38

iii
 5.8 Thermal Performance factor 39
References 40

CONCLUSION 41

iv
 List of Figures
Fig Captions Page no.
no.
1.1 Rough pipe on a surface 4
1.2 Extended surfaces 4
1.3 Grooved pipe 5
1.4 Single and double twisted tape with counter-swirl and co-swirl arrangement 5
1.5 Schematic of pipe insert 6
1.6 Wire coil inserts inside pipe 6
1.7 In-line rib arrangements with wedge pointing upward, wedge pointing
6
downward, triangular and rectangular
1.8 Coiled tube 7
2.1 Pipe with helical grooves in 3D Model 13
3.1 Solution procedure outline 18
4.1 Schematic cross-section of the circular grooved tube 25
4.2 Schematic diagram of the cross-section of the helical grooved tube with Helix
26
angle = 50°, no. of grooves =5 .
4.3 Schematic cross section of circular grooved tube 27
4.4 Pipe with Helix angle = 20° No.of turns = 5 l = 0.08 m 27
4.5 Pipe with Helix angle = 30° No.of turns = 5 l = 0.08 m 27
4.6 Pipe with Helix angle = 40° No.of turns = 5 l = 0.08 m 27
4.7 Pipe with Helix angle = 50° No.of turns = 5 l = 0.08 m 28
4.8 Pipe with Helix angle = 50° No.of fins = 4 28
4.9 Pipe with Helix angle = 50° No.of fins = 6 28
4.10 Pipes with different groove depths 29
4.11 Pipes with different groove width 29
5.1 Grid distribution of heat transfer tube 32
5.2 Skewness chart 32
5.3 Simplified model geometry 33
5.4 Comparison between the calculated value and the theoretical value in smooth
34
tubes. (A) f (B) Nu.
5.5 The effect of the fin number on the Nu and f at different helix angles. (A) Nu.
36
(B) f.
5.6 The Temperature cloud diagram and velocity cloud diagram with different fin
36
numbers. (A) N = 4. (B) N =5. (C) N = 6.
5.7 The effect of the groove width on the Nu and f at different helix angles. (A) Nu
37
(B) f
5.8 The cloud picture of velocity and temperature with different fin width. (A)w =
37
1.5 mm. (B) w = 2 mm. (C).w=2.5 mm.
5.9 The effect of the groove depth on the Nu and f at different helix angles (A) Nu
38
(B) f.
5.10 The cloud picture of velocity and temperature with different groove depths. (A)
38
d = 0.75 mm. (B)d=1mm. (C).d= 1.25 mm.
5.11 Variation of Thermal performance factor with Helix angle 39
5.12 Variation of Thermal performance factor with a)Depth of groove b) Width of
39
groove

v
 List of Tables
Fig Captions Page no.
no.
4.1 Comparison of Calculated values and Veysel O” Zceyhan 26
5.1 Comparison of factors with different meshes 32
5.2 Heat transfer Surface Area of grooved tubes 35

vi
 CHAPTER

1
INTRODUCTION

1.1 Overview
In this chapter we will be discussing importance of heat transfer enhancement and different
techniques of heat transfer augmentation.

Heat energy is very vital to our lives. It is used daily in many aspects of our life directly or
indirectly. It helps us survive. Heat transmits in mainly three ways; it transfers by convection,
conduction, and radiation. Conduction transfers heat through direct contact, and convection
transfers heat through the movement of particles and radiation transfers heat in infrared waves.
We need to convert or transfer heat for our daily demands, e.g., Cooking, Light, Cooling or
heating mechanical and electronic equipment, etc.. Heat transfer regulation to suit our needs
became a necessity for us. Overheating or overcooling can lead to failure of heat transfer
components.

Heat exchangers are extensively used in industries for heat transfer between various
substances[1] Heat exchangers facilitate contactless heat transfer among 2 fluids. Power
demand has risen very steeply in the past two to three decades because of overpopulation and
due to the development of advanced technology. To meet the energy demands, technology
developed generates a lot of heat, and heat needs to be removed swiftly for the better efficiency
and longevity of the device.

To increase heat exchangers efficiency, reducing capital costs and decreasing energy usage,
[2]Heat transfer augmentation is required, which is done by active methods, passive methods,
and compound methods. Active methods need an external source of energy to increase thermal
performance. In contrast, passive methods don't require any external source but employ a

1
modification of system design to increase thermal performance. Compound methods uses both
external source of energy and design modification for heat transfer enhancement.

Extended surfaces have proven to be useful in increasing thermal performance and increase the
efficiency and compactness of thermal systems[4]. Automotive, refrigeration and food
processing industries, etc. have been using this technology for better performance. [3]The
extended surface on various heat exchanger geometries has been studied extensively. Using
grooves[5] to increase the surface area has been considered as one of the passive methods to
increase thermal performance. Grooved channels are often encountered in electronic
equipment, solar energy, nuclear reactors, aerospace, and food processing applications.

1.2 Different methods for heat transfer enhancement

Chirag maradiya et al.[6] in their paper, said that heat transfer enhancement techniques increase
the surface area for heat exchange, generate turbulence, which promotes mixing and disturbs
the laminar sub viscous layer.

Heat transfer augmentation is a widely researched topic; it helps achieve the required
performance to make our lives better. Heat transfer augmentation techniques are divided into
mainly three types.[7,8]

1.2.1 Active Techniques

Complex procedures are applied to the design of the system to increase heat transfer, and
external power is also used to generate required changes and increase the rate of heat transfer.
It is looked upon most of the time because of the use of external energy input. These techniques
have shown a much increase in thermal performance and efficiency as the use of external power
increases energy loss.
Some of the examples of Active techniques are
1. Mechanical Aids
2. Fluid vibration
3. Surface vibration
4. Electrostatic fields
5. Jet impingement
6. Injection
7. Suction

2
1.2.2 Passive techniques
They generally use physical design adjustments to modify the fluid flow patterns by changing
surface topologies or by using inserts inflow channel. They increase the heat transfer area or
create disturbances inflow, which promotes mixing. The downside of passive methods is the
pressure drop also increases, which creates limitations in the use of passive methods. They are
better than active methods as they don't need any extra power input.

Passive techniques include increasing the roughness if surface, treating the surface, increasing
the surface area for heat transfer, causing swirl flow inside tubes, use of twisted tubes, using
additives like nano particles for increasing conduction in fluid etc..

1.2.3 Compound techniques

One or more than one technique of passive and active methods are used in compound
techniques to increase thermal performance.

1.3 Thermal Performance Enhancement Techniques

1.3.1 Treated surfaces
Altering the surface structure in a mild manner or surface coating is called a treated surface.
Single-phase heat transfer is not affected as roughness height is small. Treated surfaces are
used in boiling and condensation. Few treated surfaces are

1. Coated surfaces
2. Multi-layered surfaces
3. Machined surfaces
4. Grooved surfaces
5. Modified small fin surfaces

1.3.1.1 Boiling
In enhanced boiling treated surfaces, bubble formation happens on the surface because of
massive vapor trapping.

1.3.1.2 Condensation
Treated surfaces increase drop wise condensation, and it prevents surface wetting. It provides
better removal of vapor at a cold heat transfer interface. Heat transfer can be increased up to
100 times by treated surfaces.

3
1.3.2 Rough surfaces
Surface roughness creates turbulence near-wall, which causes higher mixing, and heat transfer
is also increased; turbulence disturbs the viscous laminar sub layer. Roughness in tubes is
employed in both inside and outside the tube for heat transfer augmentation. Structured
roughness is obtained by modifying surface in a two dimensional or three-dimensional pattern,
and they can be produced by machining, casting, or welding.

Fig 1.1 Rough surface inside a pipe[15]

1.3.3 Extended surfaces

Heat transfer is increased by using extended surfaces, and it is used where heat transfer
coefficients are low. [14] The addition of fins increases the heat exchange area on the body.
Extended surfaces are crucial in electronic equipment as the heat transfer area is very less.
Finned surfaces are used in automobiles, refrigeration, air compressors, power plants,
electronic equipment, etc..

Fig 1.2 Extended surfaces[13]

4
1.3.4 Grooves inside the pipe
When circular transverse grooves are used inside a pipe, inner surface temperatures are found
to reduced compared to plain tubes.[11] heat transfer is increased owing to increment in heat
transfer surface area and destruction of the laminar sub-layer. Pressure drop also increase
with the use of grooves inside the pipe. There are different kinds of grooves used in a pipe
like transverse grooves, helical grooves, longitudinal grooves and different shapes of grooves
are also used.

Figure 1.3 Grooved pipe[11]

1.3.5 Twisted tape

Twisted tape[6] causes swirl flow or secondary flow, which causes heat transfer augmentation.
The pressure drop penalty is less for twisted tape. The heat exchanger size can be decreased
remarkably with it. It has a better economic benefit over the cost of equipment. Even though
heat transfer is increased, the thermal performance factor is limited to 1.05.

Fig 1.4 Single and double twisted tape [6].

5
1.3.6 Pipe Inserts
The pipe insert[12] was used for heat transfer augmentation in a pipe. Pipe insert modifies
velocity and temperature profiles and increases heat transfer.

Fig. 1.5. Schematic of pipe inert [6].

1.3.7 Wire coil inserts

TPF is increased with a decrease in pitch of wire coil and TPF with increase in the distance of
coil from the inner surface of pipe[6].

Fig 1.6. Wire coil inserts inside the pipe [6]

1.3.8 Rib & Groove

Fig. 1.7. Ribs inside a pipe [6]

6
Ribs and grooves create fluid blockades at the wall, [6]which causes turbulence and, in turn,
increases heat transfer. Ribbed pipe performs better in laminar flow. As Reynolds number
increases, its efficiency decreases.

1.3.9 Coiled tubes

Fig 1.8 Coiled tube [6]

Coiled tubes cause secondary flows due to change in velocity because of the curved surface of
the pipe. The curvature of coils induces secondary flows because of centrifugal force on fluid
flow. They are used in industrial machine boilers. Water heaters, chemical process reactors,
kidney dialysis machines and food processing industries, etc..

Most of the studies on heat transfer augmentation by helical grooves, considered transverse
circular grooves, helical fins inside the pipe, and helical grooves with limited variations. In my
present study, numerical analysis of heat transfer characteristics in a helically grooved pipe for
a turbulent flow has been done. Maximum thermal performance is calculated by varying the
helical angle, no. of starts, width, and depth of the groove.

7
1.4 Organization of thesis
Chapter 1 presents a general background on heat transfer and its importance. It explains about
the importance of heat transfer augmentation and various techniques to increase heat transfer.
It also explains about grooved surface use for heat transfer augmentation.

Chapter 2 presents an overview of supporting literature for heat transfer enhancement by

grooves inside the pipe. Various studies of heat transfer enhancement by using grooves, fins
inside the pipe were mentioned.

Chapter 3 presents basics of computational fluid dynamics which help in numerical

simulation of helical grooves inside the pipe for a turbulent flow. Governing equations for
fluid flow and heat transfer and various turbulence models are also discussed.

Chapter 4 presents an overview of problem and methodology used to solve the problem.
Validation of model, Geometry of models under study, boundary conditions, turbulence
model used to solve are discussed in this chapter.

In Chapter 5, study of heat transfer and fluid flow in turbulent flow for helical grooves inside
pipe is carried out. The results are presented and the model with highest thermal
performance factor is presented.

8
References
1. L. M. Jiji, Heat convection, 2nd ed, New York: Springer Berlin Heidelberg, 2009.
2. J. P. Holman, Heat transfer, 10th ed, New York: McGraw-Hill, 2009.
3. S. V. Patil and P. V. Vijay-Babu, "Experimental studies on mixed convection heat
transfer in laminar flow through a plain square duct," Heat and Mass Transfer, Vol.
48, pp. 2013-2021, 2012.
4. Zimparov V 2002 Energy conservation through heat transfer enhancement techniques.
Int. J. Energy Res. 26: 675–696
5. Sompol Skullong et al. Heat transfer augmentation in a solar air heater channel with
combined winglets and wavy grooves on absorber plate.
6. Chirag maradiya, jeetendra vadher, Ramesh Agarwal. Heat transfer enhancement
techniques and their thermal performance factor. Beni-Suef University Journal of
Basic and Applied Sciences Volume 7, Issue 1, March 2018, Pages 1-21
7. B.Adrian and K. Allan D. Heat transfer enhancement. In Heat Transfer Handbook,
Chapter 14, pg.1033, -1101, Wiley-interscience, 2003.
8. Bergles, A.E. ―Techniques to augment heat transfer.‖ In Handbook of Heat Transfer
Applications (Ed.W.M. Rosenhow), 1985, Ch.3 (McGraw-Hill, New York).
9. Guenrikh A. Dreitser. Efficiency of Heat Transfer Enhancement in Heat Exchangers.
Article in Heat Transfer Research 32(7-8):9 • January 2001.
10. Mousa Aadmi. Heat transfer characteristics of thermal energy storage for phase
change material. Energy Volume 85, 1 June 2015, Pages 339-352
11. Veysel Ozcheyhan and Necdet Altuntop . Heat transfer & thermal stress analysis in
grooved tubes. Sadhana Vol. 30, Part 4, August 2005, pp. 537–553.
12. Kesav Kumar Sridharan. Experimental investigation on the thermal performance of
helical grooved flat heat pipe.
13. Retrieved from https://www.theengineeringconcepts.com/fin-an-extended-surface/.
14. Pitak Promthaisong. Numerical investigation on turbulent forced convection and heat
transfer characteristic in spirally semicircle-grooved tube. International Journal of
Mechanical and Materials Engineering volume 11, Article number: 9.
15. Deng Li et al. Effects of Nozzle Inner Surface Roughness on the Performance of
Self-Resonating Cavitating Waterjets under Different Ambient Pressures.
16. Zhanwei Liu. Numerical Analysis of Turbulent Flow and Heat Transfer in Internally
Finned Tubes. Frontiers in Energy Research 7:64 • July 2019.

9
 CHAPTER

2
LITERATURE REVIEW

2.1 Overview
The aim of this research is to improve the thermal performance by using the helical grooves
inside the circular heat pipe by increasing the heat transfer area inside the tube.

Grooved surface technology has been shown promise to increase heat transfer. Grooved
channels are easy to implement, cost of production and maintenance cost is also less compared
to other passive techniques for heat transfer augmentation. Brognaux et al. (1997) [1] analyzed
Nusselt number and resistance coefficient for single-grooved and cross-grooved microfin
tubes. Micro-fin pipes has heat transfer two times to that of smooth tubes. According to M.
Greiner et al. [2], grooved surface in a rectangular cross-section water channel show heat
transfer augmentation of about sixty-five percent in the Reynolds number range 1200 to 4800.
KadirBilen et al[3]. found that, heat transfer augmentation is obtained up to 47% for the
rectangular shaped groove and 63% for the circular shaped groove, 58% for the trapezoidal
shaped groove, when compared to smooth tube.

The thermal performance coefficient is better in grooved tubes than smooth tubes. According
to S Skullong et al.[4], the grooves with Trapezoidal Winglets provide a significant heat
transfer enhancement compared to a plsin pipe. Jian Liu et al.[5] studied heat transfer
characteristics in square channels with cylindrical grooves and determined the optimal
configuration for increasing heat transfer rates with the least pressure drop possible. Cylindrical
and square groove ribs have nearly the same overall heat transfer increase, but pressure loss is
much less in cylindrical compared to square ribs. [11]The use of grooved surfaces has increased
heat transfer rate and resistance coefficient, the increase in heat transfer rate is overshadowed
by pressure drop and can increase thermal performance to a limit.

10
Heat transfer augmentation in grooved tube technology is done by few elements like reducing
hydraulic diameter, it creates swirl in the flow, which is generated by helical grooves, and heat
transfer area between pipe and fluid is increased, which increases heat transfer coefficient.
Blocking of flow[12] at the wall causes mixing(causes heat transfer enhancement). In grooved
pipe pressure, the drop is also simultaneously increased, which should be put in check. Various
research works have been done on grooved tubes, which increases both heat transfer rate and
pressure drop, but the thermal performance coefficient is also increased, which shows the
potential to be used in industries.

2.2 Helical grooves in turbulent flows

An experimental investigation was done by Putu Wijaya Sunu et al.[7] for an optimum number
of grooves for decreasing pressure drop. Pressure drop and drag are calculated for two, four,
eight, and twelve grooves, the distance between grooves 39.8, 19.4, 9.2, 5.8, 4.1, and 3.1 mm
respectively, and for Reynolds number of 15038, 18145, 22156, 20638. It has been found that
the optimum number is eight, which resulted in the least pressure drop among all of them. The
grooves cut into internal walls increased surface area for heat exchange, and the pressure drop
is also reduced.

Kadir Bilen et al.[8], tested different shapes to find out which has a high thermal performance
coefficient. Heat transfer enhancement is sixty-three percent for the circular groove, forty-
seven percent for the rectangular groove, and fifty-eight percent for the trapezoidal groove. The
results were compared to a smooth pipe at Reynolds number of 38,000. It is found that grooved
tubes have a higher thermal performance coefficient.

Zhanwei Liu et al. [9] studied heat transfer in helically finned tubes for turbulent flow. Helical
fins are constructed inside the tube, and heat transfer characteristics and flow characteristics
are studied. Geometric parameters like number of fins, helical angle of fins, width, and height
are varied. The study shows that both the Nusselt number increase with the increase when
number of fins increase and helical angle increase from 10° to 40°, and resistance coefficient
increase with the increase when number of fins increase and helical angle increase from 10° to
40°, Nusselt number and resistance coefficient both increase when height of fins increase.
Nusselt number increases considerably when the helical angle is more than 20°. When fin width
changes, both the Nusselt number and friction coefficient doesn’t change much. When fin
shapes are changed, triangular fins had the maximum performance compared to rectangular
and circular fins.

11
Veysel Őzceyhan et al. [6] did numerical analysis on transverse grooves inside pipes, heat
transfer, and thermal stress has been studied. 4 types of pipes with three velocities of water
have been studied. On the outer surface of pipe, a constant temperature of 400° C was
maintained. Distance between grooves is varied and thermal characteristics have been studied.
Maximum thermal stress is obtained when the distance between the grooves is equal to the
diameter of the tubes,

From an experimental investigation was done by Michael K. Jensen, physically-based

correlations were developed for the Nu and resistance coefficient by using experimental data
from the analysis conducted on different fin geometric configurations for internally finned
tubes for turbulent flow . Water and ethylene glycol are used as fluids for the analysis. The
smooth tube was used to test rig, data reduction, methodology, and act as a baseline reference
for finned tube results.

Pitak Promthaisong et al. [10] studied turbulent forced convection in a spiral semicircle
grooved tube. Swirling flow is developed in semicircle groove tubes with depth ratio greater
than 0.06, and the heat transfer rate is high, when depth ratio is more and pitch ratio is less.
The optimum TPF is 1.11 is at a depth ratio of 0.06, and a pitch ratio of 1.4 and a Reynolds
number of 5000.

In my present study, numerical analysis was done on rectangular helical grooves inside the
pipe, heat transfer characteristics like the Nusselt number and resistance coefficient were
calculated, and the thermal performance factor was also calculated with four-helix angles, three
widths, and depths of grooves and at four-helix angles.

12
2.4 Objectives of present work
The objective of this work is numerical investigation of a helical grooves inside the heat pipe.
An increase in thermal efficiency is calculated with helical grooves and compared with the
smooth pipe.

Fig 2.1. Pipe with Helical grooves in 3D Model

The foregoing literature contains a study on heat transfer and fluid flow characteristics on a
helically grooved pipe, with varying geometrical configurations of groove. Three different
groove widths and three groove depths are considered. Four different helical angles are used
to carry out analysis and three number of turns/grooves are considered. CFD is used to find the
influence of this varying geometrical configurations on heat transfer enhancement. The aim
of the analysis is to conduct a numerical analysis to study how geometrical variations are
affecting the heat transfer enhancement of the helically grooved pipes and finding the optimal
geometric configuration for best thermal performance.

Nusselt number and friction factor are calculated at 4, 5 & 6 grooves, each at 20°, 30°, 40° &
50° helix angles, and the groove depth and groove width are fixed 1 mm & 2mm. Nu and
resistance coefficient are calculated at widths of 1.5, 2 & 2.5 mm and at the depth of 1 mm
each at 20°, 30°, 40° & 50° helix angles. Nu and resistance coefficient are calculated at depths
of 0.75, 1 & 1.25 mm and at a width of 2 mm each at 20°, 30°, 40° & 50° helix angles. Thermal
performance is calculated for 28 different cases, and optimum conditions are found out.

13
References
1. Brognaux L J, Webb R L, Chamra L M, Chung B Y 1997 Single-phase heat transfer
in micro-fin tubes. Int. J. Heat Mass Transfer 40: 4345–4357.
2. M. Greiner, R.-F. Chen, R. A. Wirtz. Heat Transfer Augmentation Through Wall-
Shape-Induced Flow Destabilization. J. Heat Transfer. May 1990, 112(2): 336-341
3. Kadir Bilen. The investigation of groove geometry effect on heat transfer for
internally grooved tubes. Applied Thermal Engineering 29(4):753-761 · March 2009
4. Sompol Skullong et al. Heat transfer augmentation in a solar air heater channel with
combined winglets and wavy grooves on absorber plate.
5. Jian Liu. Enhancement of Heat Transfer in a Square Channel by Roughened Surfaces
in Rib-Elements and Turbulent Flow Manipulation. International Journal of
Numerical Methods for Heat and Fluid Flow 27(4) · April 2017
6. Veysel Ozcheyhan and Necdet Altuntop . Heat transfer & thermal stress analysis in
grooved tubes. Sadhana Vol. 30, Part 4, August 2005, pp. 537–553.
7. Putu Wijaya Sunu Optimal Grooves Number for Reducing Pressure Drop.
Contemporary Engineering Sciences, Vol. 9, 2016, no. 22, 1067 – 1074
8. Kadir Bilen. The investigation of groove geometry effect on heat transfer for
internally grooved tubes. Applied Thermal Engineering 29(4):753-761 • March 2009
9. Zhanwei Liu. Numerical Analysis of Turbulent Flow and Heat Transfer in Internally
Finned Tubes. Frontiers in Energy Research 7:64 • July 2019.
10. Pitak Promthaisong. Numerical investigation on turbulent forced convection and heat
transfer characteristic in spirally semicircle-grooved tube. International Journal of
Mechanical and Materials Engineering volume 11, Article number: 9.
11. Shankara Murthy.H.M, Dr. Ramakrishna. N. Hegde A critical review of combined
augmentation techniques used for heat transfer enhancement in heat exchangers.
NCAMES-2016.
12. Zimparov V 2002 Energy conservation through heat transfer enhancement techniques.
Int. J. Energy Res. 26: 675–696

14
 CHAPTER

3
BASICS OF
COMPUTATIONAL FLUID DYNAMICS

3.1 Overview
Computational Fluid Dynamics helps fluid mechanics to deal with solving complex problems
by employing numerical methods. CFD integrates the concepts of mathematics, computer
science, engineering, and physics for modeling fluid flow. These models are then solved to find
the solutions to problems of various fields of engineering and science; however, these models
are worth using only when the results they provide are near to actual-world situations. [1] The
accurateness of the simulation results relies on many factors like computational power of the
device, the type of software used, how complicated the situation is, and the method the user
uses to get the results. The present chapter provides a brief introduction to Computational Fluid
Dynamics, its history, uses and advantages, the approach needed to get proper CFD results,
various methods and models employed in CFD, etc.

3.2 Introduction to CFD

To solve a physical problem, [2] we generally have experimental, theoretical, and numerical
methods. Experimental methods require large setups of the physical models to start the study
or to make the prototype of the model. Sometimes it's even not possible to make a model at all.
The other method that is theoretical is a good option where governing equations are solved
analytically to study the behaviour. Excellent mathematical skills are required to solve these
equations without making assumptions and eliminating most of the terms. Assumptions and
elimination of terms affect the accuracy of the result. [3] For complex physics, solutions are
difficult to reach as a large number of iterations are needed, as the number of variables required
is high.

CFD is a method that has accelerated the solutions of numerical methods for the fluid flow
problems. In CFD, one of the most fundamental consideration is the treatment of a continuous
15
fluid element in the computational environment. The discretization of the spatial domain to
solve the Navier stokes equation or the other equations derived from it is one of the approaches
of the CFD. The computational domain is divided into small elements called mesh or grid,
each of which will be solved to obtain the desired result. Also, there is a method of directly
solving Navier stokes equations called direct Numerical methods. It is, however, not so much
in use due to the high requirement of computational power.

3.3 Advantages of CFD

CFD is powerful and is used in numerous applications by scientists and engineers of various
fields. Some of the advantages are

1. Thorough understanding of fluid flow and heat transfer characteristics

2. Variation of characteristics with change of physical design can be calculated using CFD
and costs lesser than laboratory testing.
3. CFD helps vary the situations accordingly to our convenience and helps us reach an
optimum value to use in a real-world situation.
4. CFD can be used in simulating high-temperature circumstances and dangerous
situations where it's not possible to measure the required parameters.

3.4 Applications of CFD

CFD is applied in many industrial and non-industrial applications [5] are:
 Aerodynamics: Lift and drag on vehicles and aircraft.
 Power plant: combustion in engines and fluid motion in turbines, rotating passages,
diffusers, etc.
 Electrical and electronics engineering: Equipment cooling.
 Chemical engineering: species reaction, mixing, polymer moulding, etc.
 Building environment: wind loading and heating ventilation.
 Marine engineering: offshore structural loads, wave behaviour
 Environmental engineering: distribution and pollution, and effluents.
 Hydrology and oceanography: flow in rivers, oceans, etc.
 Meteorology: weather prediction.
 Biomedical: blood circulation.

16
3.5 Basic Approach to use CFD
CFD codes [6] are structured based on the numerical algorithm and are designed to tackle
problems on the fluid flow and heat transfer. Several commercial codes are available, having a
sophisticated user interface for easy parameter input and examination of the result. All codes
follow the three essential stages. (1) Preprocessing (2) solving, and (3) post-processing.

3.5.1 Pre-processing
In Pre-processor, inputs required for the flow domain were given in the user-friendly software
interface, which will be used by the solver to obtain the solution to the problem.

The steps in this stage are:

 Defining required computational domain.
 Division of the geometry into smaller cells: Meshing
 Naming the required domains and surfaces for further insertion of boundary conditions.
 Defining fluid properties: using the named selections to insert the boundary conditions
to solve the variables at each node starting from boundary cells.

The number of elements in the domain can represent the correctness of the solution; a greater
number of cells can lead to better accuracy of the solution.

3.5.2 Solving the Problem

CFD code contains discretization techniques for solving the convection, diffusion, source
terms, and transport phenomena. The solver uses the subsequent steps

1. Integration of the heat transfer and fluid flow equations in CV.

2. Discretization of resulting equations into algebraic equations.
3. Solving algebraic equations through an iterative procedure.

These are three distinct techniques for numerical discretization are:

1. Finite element method

2. Finite difference method
3. Finite volume method

17
 Fig 3.1 Solution procedure outline

3.5.3 Post-processing
The post-processing field has been developed to a great extent. Easy to understand and find the
differences were essential to make progress, which was possible by proper visualization tools
and inbuilt mathematical calculators to find the volume integrals, surface integrals, etc..

3.6 Discretization Methods in CFD

3.6.1 Finite difference method (FDM)
The finite difference method[7] is based upon the differential form of partial differential
equations. The computational domain is converted into mesh by using the meshing operation
in which the whole geometry is divided into smaller elements, and the solution is calculated at
every node. The discretization results in a system of equations of the variable at nodes, and
after the solution are calculated, a discrete representation of the solution is present.

3.6.2 Finite element method (FEM)

The finite element method is mostly used for solid structures. The computational domain is
divided up into smaller finite elements, and the solution in each element is calculated by using
basis functions. The finite element method is stable than the Finite volume method approach.
Stability and robustness in the finite element method are superior compared to Finite volume
or finite difference method but consume more memory compared to the Finite volume method.

3.6.3 Finite Volume method

The Finite Volume method is normally used method in commercial software. The finite volume
method uses a discrete CV to find the solution. Finite volume method discretization uses an

18
integral form of partial differential equations to find solutions. The resultant system of
equations contains fluxes of the conserved variable, and the calculation of flux.es is very
significant in the Finite Volume Method. The basic advantage of the Finite Volume method
over the Finite Difference method as it does not require the use of structured grids. The required
properties are found for every element instead of a node. Finite Volume method can handle
discontinuities in solution.

3.7 Governing Equations of Fluid Dynamics

To predict [8] the actual behaviour of the flow in the physical world, each CFD package has
to solve a set of equations that govern these flows. For the CFD user, it is necessary to have an
idea of these governing equations and also the basic idea of the behaviour of fluid needed to be
analysed, the physics of the fluid flow is generally governed by three fundamental equations:

3.7.1 Continuity equation

The continuity equation is fundamentally the equation of conservation of mass, and it is derived
by applying mass conservation on the fluid entering and leaving the control volume. The
continuity equation for an incompressible fluid in unsteady 3D flow can be written as

𝜕𝜌 3 𝜕 (3.1)
+∑ (𝜌𝑢𝑖 ) = 0
𝜕𝑡 𝑖=1 𝜕𝑥𝑗

3.7.2 Momentum equation

The momentum equation for the unsteady three directional flow can be written as:

𝜕𝜌 3 𝜕 𝜕𝑃 3 𝜕𝜏
𝑖𝑗
+∑ (𝜌𝑢𝑖 𝑢𝑗 ) = − +∑ + 𝜌𝑓𝑖 (3.2)
𝜕𝑡 𝑖=1 𝜕𝑥𝑗 𝜕𝑥𝑗 𝑗=1 𝜕𝑥𝑗

The left hand side of the equation represent the inertia forces. The Right hand side of the
equation denotes pressure forces, the 2nd term represents the surface forces, and the 3rd term
denotes the body force.

3.7.3 Energy equation

It is mathemaical formulation of the 1st law of thermo ynamics or energy conservation of. It is
t d

needed to find the temperature distribution in a flow field. In the absence of radiation, there are
no distributed energy sources. The energy equation for the unsteady three dimensional fluid
flow can be given as:

𝑑𝑇 𝑑𝑃
𝜌𝐶𝑝 = 𝑑𝑖𝑣 (𝜆 𝑔𝑟𝑎𝑑 𝑇) + 𝑇𝛽 +𝜙 (3.3)
𝑑𝑡 𝑑𝑡

19
Where viscosity energy dissipation function is defined as:

2 𝜕𝑢𝑖 (3.4)
𝜙= 𝜇(𝑑𝑖𝑣. 𝑢)2 + 2𝜇𝑆𝑖𝑗
3 𝜕𝑥𝑗

1 𝜕𝑢𝑖 𝜕𝑢𝑗 (3.5)

𝑆𝑖𝑗 = ( + )
2 𝜕𝑥𝑗 𝜕𝑥𝑖

3.8 Turbulence models

Fluid flow is turbulent when the transport properties[9] like mass, momentum, and energy
have periodic and irregular fluctuations in space and time. Turbulence leads to enhanced
mixing. Reynolds number is used as a characterize different types of flow. Several turbulent
models have been developed to model the behaviour of turbulent models. Choosing a turbulent
model depends on the physics of the fluid flow and level of the accuracy required, accessible
resources, and time available for simulation.

3.8.1 Zero equation model

Mixing length model – velocity profiles in unbounded flows, the order of magnitude of mixing
length in boundary layer flows.

3.8.2 One equation model

Spalart- Allmaras model

3.8.3 Two equation models

 Standard k-ε model
 RNG k-ε model
 The realizable k-ε
 The standard k-ω model
 Shear stress Transport k-ω model.

3.8.4 Seven equation model

Reynolds stress model avoids isotropic formulation of turbulent viscosity, suitable for complex
three-dimensional flows who strong swirl/rotation, computational time , costly in CPU effort.
Few other models are:

3.8.5 DNS (Direct Numerical simulation)

It can be used for all the levels of turbulent motion, extremely expensive scheme, or sometimes
untraceable, for complex three-dimensional problems.

20
3.8.6 Large Eddy simulations
Solves directly space filtered, time-dependent equations. Large eddies are clearly calculated.
For smaller eddies, their effect on the flow pattern is considered.

3.9 Two equation models

3.9.1 Standard k-ε mode
The standard 𝑘 − 𝜀 model [10] is one of the widely used two-equation models. It is used for
large Reynolds number turbulent flows. k and ε denote turbulent kinetic energy and dissipation
rate of turbulent kinetic energy, respectively. 𝑘 & 𝜀, are calculated from the transport equations.

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝑘
(𝜌𝑘) + (𝜌𝑘𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 + 𝐺𝑏 − 𝜌𝜀 (3.6)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜎𝑘 𝜕𝑥𝑗

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜀 𝜀 𝜀2 (3.7)
(𝜌𝜀) + (𝜌𝜀𝑢𝑖 ) = [(𝜇 + ) ] + 𝐶1𝜀 (𝐺𝑘 + 𝐶3𝜀 𝐺𝑏 ) − 𝐶2𝜀 𝜌
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜎𝜀 𝜕𝑥𝑗 𝑘 𝑘

The turbulent viscosity is calculated from

𝜅2 (3.8)
𝜇𝑡 = 𝜌𝐶𝜇
𝜖
C1ε = 1.44, C2 = 1.9, and Cμ = 0.09.

3.9.2 Realizable k-ε model

The realizable k-ε model varies from the standard k-ε model in main.ly two ways[10].

→ The realizable k-ε model us.es a new formulation for the turbulent viscosity.
→ A new equation for the dissipation rate, ε has been derived fr.om an exact transport
equation of me.an squa.re vorticity fluctuation,
The term realizable means that the model satisfies certain mathematic.al constraints on the
Reynol.ds stress, consistent with the physics of turbulent flows.

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝑘
(𝜌𝑘) + (𝜌𝑘𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 + 𝐺𝑏 − 𝜌𝜀 − 𝑌𝑀 (3.9)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜎𝑘 𝜕𝑥𝑗

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜀 𝜀2 𝜀
(𝜌𝜀) + (𝜌𝜀𝑢𝑖 ) = [(𝜇 + ) ] + 𝜌𝐶1 𝑆𝜀 − 𝜌𝐶2 + 𝐶1𝜀 𝐶3𝜀 𝑃𝑏 + 𝑆𝜀 (3.10)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜎𝜀 𝜕𝑥𝑗 𝑘 + √𝜈𝜀 𝑘

C1ε = 1.44, C2 = 1.9, σk = 1.0, σε = 1.2.

3.9.3 RNG k – ε model

The Renormalization Group theory (RNG) model was proposed by Yahot & Orszag, It is based
on model transport equations for the turbulence kinetic energy k and its rate of dissipation ε.

21
Turbulent kinetic energy equation:
𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝑘
(𝜌𝑘) + (𝜌𝑘𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 + 𝐺𝑏 − 𝜌𝜀 (3.11)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜎𝑘 𝜕𝑥𝑗

Dissipation rate of turbulence kinetic energy equation:

𝜕 𝜕 𝜕 𝜕𝜀 𝜀 𝜀2
(𝜌𝜀) + (𝜌𝜀𝑢𝑖 ) = [𝛼𝜖 𝜇𝑒𝑓𝑓 ] + 𝐶1𝜀 (𝐺𝑘 + 𝐶3𝜀 𝐺𝑏 ) − 𝐶2𝜀 𝜌 − 𝑅𝜀 (3.12)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑖 𝜕𝑥𝑗 𝑘 𝑘

3.9.4 Shear Stress Transport (SST) k-ω model

The SST k-ω model is a hybrid two equation model that combines the advantages of both k-ε
and k-ω models. The k-ω model performs much better than k-ε models for boundary layer
flows. It is based on the transport equation of turbulence kinetic energy (k) and specific
dissipation rate (ω).

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜅 (3.13)
(𝜌𝜅) + (𝜌𝜅𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 − 𝛽1 𝜅𝜔
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝜅 𝜕𝑥𝑗

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜔 1 𝜕𝜅 𝜕𝜔 (3.14)
(𝜌𝜔) + (𝜌𝜔𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝜔 − 𝛽2 𝜔2 + 2(1 − 𝐹1 )𝜎𝜔.2
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝜔 𝜕𝑥𝑗 𝜔 𝜕𝑥𝑗 𝜕𝑥𝑗

where Gk is the generation of turbulence kinetic energy, Gω is the generation of specific

dissipation rate

3.9.5 Standard k-ω model

The standard k-ω model incorporates modification of low Reynolds number effect. Like the
S.S.T k-ω model, it is based in transport equation of turbulence kinetic energy and specific
dissipation rate.

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜅
(𝜌𝜅) + (𝜌𝜅𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 − 𝛽1 𝜅𝜔 (3.15)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝜅 𝜕𝑥𝑗

𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜔 (3.16)
(𝜌𝜔) + (𝜌𝜔𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝜔 − 𝛽2 𝜔2
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝜔 𝜕𝑥𝑗

Model constants β1 and β2 are 0.072 and 0.072.

3.10 Implicit and Explicit scheme

While calculating flow parameters with the CFD tool, [12] spatial and temporal discretization
of the domain is necessary. Commercial software automatically chooses time marching
criterion for steady-state problems. While for transient problems, the user can specify time
steps. There are two types of temporal discretization systems that can be used.

22
3.10.1 Explicit scheme
Here the value of the property at current time steps is calculated explicitly from previously
known time step solutions. The property value can be calculated as:

𝜙(𝑡) = 𝑓(𝜙(𝑡 − Δ𝑡)) (3.17)

Where ϕ(t) = property at time ‘t’ and Δt = time step size.

3.10.2 Implicit scheme

In the implicit scheme, property value can't be measured directly. The property value at a given
time step is the function of the property value at a previous at previous as well as property value
at a current time.
𝜙(𝑡) = 𝑓(𝜙(𝑡 − Δ𝑡)), 𝜙(𝑡) (3.18)

Implicit schemes are more stable than explicit schemes. Explicit schemes need to satisfy the
courant-fried rich-levy (CFL) condition in order to guarantee stability.
𝑈𝛥𝑡
𝐶𝐹𝐿 =
𝛥𝑥 (3.19)
Δt = time step, Δx = cell size, U = free stream velocity

23
References

1. J.A.M. Kuipers, W.P/M van Swaaij Computational Fluid Dynamics Applied To

Chemical Reaction Engineering . Advances in Chemical Engineering Volume 24,
1998, Pages 227-328.
2. Dmitri Kuzmin. Introduction to Computational Fluid Dynamics. Institute of Applied
Mathematics. University of Dortmund,
3. Md Lokman Hosain, Literature Review of Accelerated CFD Simulation Methods
towards Online Application. Energy Procedia Volume 75, August 2015, Pages 3307-
3314.
4. (Jun. 2017). “Computational Fluid Dynamics And Applications.” Retrieved from
http://crbtech.in/CAD-CAM-Training/computational-fluid-dynamics-applications/
5. CFD & ANSYS FLUENT Retrieved from
https://www.slideshare.net/muhammadshujan/cfd-ansys-fluent
6. Basics of Grid Generation for CFD Analysis. Retrieved from
https://www.learncax.com/knowledge-base/blog/by-category/cfd/basics-of-grid-
generation-for-cfd-analysis
7. The finite element method. Retrieved from
https://en.wikipedia.org/wiki/Finite_element_method
8. Jiri Blazek PhD, Governing Equations in Computational Fluid Dynamics: Principles
and Applications (Third Edition), 2015
9. J. M. McDonough, Introductory lectures on turbulence Physics, Mathematics And
Modeling.
10. Taiwo Oluwasesan, Numerical Investigation of Heat Transfer and Fluid Flow in
Tubes Induced with Twisted Tape Inserts

24
 CHAPTER

4
MATERIALS AND METHODOLOGY

4.1 Validation of present project

For our present design, initially validation is performed. Heat transfer and thermal stress
analysis in grooved tubes by VEYSEL O¨ ZCEYHAN and NECDET ALTUNTOP is
considered. Heat transfer characteristics and thermal stress distributions are studied, flow is
turbulent and constant temperature is maintained on the outer-surface of pipe. CFD tools are
used to solve the governing equations numerically. Plain pipes are used for comparison with
grooved pipes/ the distance between two grooves is varied and heat transfer characteristics are
studied.

Fig 4.1 Schematic cross-section of the circular grooved tube

25
Heat transfer characteristics are studied for pitch equal to d/2, d & 3d/2 & 2d, and for fluid
velocity of 0.3 m/s.

Table 4.1 Comparison of Calculated values and Veysel O" Zceyhan

Veysel O¨ Zceyhan Calculated values

Tsurface 410.47 K 412.13 K
Tout 301.23 K 301.67 K
f 0.0096 0.0105
Measured values are in an acceptable range of 5% difference. In our present study, analysis is
done using helical grooves instead of circular grooves.

4.2 Design and Methodology

4.2.1 Physical design of grooved pipe
Physical design and groove geometry were taken from Veysel O¨ Zceyhan, which has a length
of 0.08 m and groove has a depth of 1 mm and a width of 2 mm.

Physical design of the grooved pipe with different pitch distances, helix angles, number of
turns, groove depths and groove widths are presented below.

Fig 4.2 Schematic diagram of the cross-section of the helical grooved tube with Helix angle = 50°, no. of
grooves =5 .

26
 Fig 4.3 Schematic diagram of cross section of helical groove

Fig 4.4 Pipe with Helix angle = 20° No.of turns = 5 l = 0.08 m

Fig 4.5 Pipe with Helix angle = 30° No.of turns = 5 l = 0.08 m

Fig 4.6 Pipe with Helix angle = 40° No.of turns = 5 l = 0.08 m

27
Fig 4.7 Pipe with Helix angle = 50° No.of grooves = 5 l = 0.08 m

Fig 4.8 Pipe with Helix angle = 50° No.of grooves = 4

Fig 4.9 Pipe with Helix angle = 50° No.of grooves = 6

28
 Fig 4.10 Pipes with different groove depths

Fig 4.11 Pipes with a different groove width

4.2.2 Methodology
The helical grooves are placed along the axis with constant pitch and helix angle. The pipe
studied have an inner diameter of 0.09m and an outer diameter of 0.11m. Helical grooves have
the depth of 1 mm and width of 2 mm and helix angles of 20°, 30°,40°,50° at the pitch of 75
mm, 53 mm, 36 mm, 23 mm. Helical grooves of 4 turns, five turns and six turns at helical
angles of 20°, 30°, 40°, 50° have been studied. Helical grooves with widths of 1.5 mm, 2.5 mm
and depths of 0.75 mm, 1.25 mm at helical angles of 20°, 30°, 40°, 50° have been studied. We

29
are taking a length of 0.08m as standard and are changing helix angles, no. of turns width,
depth of the groove and changes in the thermal performance are calculated. Pitch is considered
as the length of the computational domain for all the cases.

4.2.3 Assumptions
Following conditions are assumed while solving the problem

1. The flow is assumed to be fully developed.

2. The flow is steady, and two-dimensional.
3. Thermal conductivity of the tube material does not change with temperature.
4. The tube material is homogeneous and isotropic.
5. No slip boundary condition.
6. Constant Heat flux is applied through the external surface of the tube.
7. The flow is assumed to be fully turbulent, and the effects of molecular viscosity are
negligible.

30
 CHAPTER

5
NUMERICAL ANALYSIS

5.1 Overview
In this chapter, thermal and hydraulic characteristics i.e., Nusselt number and friction factor of
turbulent flow inside the helically grooved tubes are investigated numerically with the aim of
determining which groove dimension gives the best performance, which is calculated using
thermal performance factor. The effects with the changes in the helix angle, groove width,
groove pitch and groove width are considered.

5.2 Grid generation

The meshing is done in such a way such that increase in number of elements doesn’t vary the
result much. For perfect meshing, inflation was used near inner pipe wall surface and face,
edge & body sizing on typical edges, faces and bodies were used. Mesh consists of maximum
hexagonal elements, with tetrahedral elements for inflation.
For accurate simulation, mesh near the wall is appropriately sized, y+ value is taken as 1. The
first layer height was taken as 0.0289 mm.

31
 Fig 5.1 Grid distribution of heat transfer tube

Fig 5.2 Skewness chart

The average Skewness of the grid is 0.217, which is below 0.7, so the grid generation is
reliable.

5.3 Grid Independence test

Grid independence test is performed to confirm that required number of elements are used.

Table 5.1 Comparison of factors with different meshes

Standard mesh Mesh 2 Mesh 3

Nodes 398154 528196 687943
Elements 1401592 1936020 2312860
Nu 147.875 148.005 148.256
f 0.14024 0.14056 0.14062

32
When grid numbers increase from 398154 to 528196, the difference of both Nu & f is in the
acceptable range of 6%.

Fig 5.3 Simplified model geometry

5.4 Boundary Conditions

• We set inlet boundary as velocity inlet, the temperature of which is 300 K while the
outlet boundary as outflow.

• The fluid domain is taken as single-phase water with constant physical properties.

• Inlet water velocity is taken as 0.5 m/s.

• The constant heat flow boundary condition and the given heat flux is q = 1,10,000
W/m2.

• The solid domain is taken as steel.

5.5 Computational Formulation

k-ω SST model is a hybrid two equation model that combines the advantages of both k-ε and
k-ω models. The k-ω model performs much better than k-ε models for boundary layer flows.
SST is a good compromise between k-e and k-w models. k-ω SST model is selected to obtain
a detailed flow condition near the tube wall. The coupling solution of pressure and velocity is
SIMPLE algorithm, and the momentum and energy equations are solved by the second-order
upwind scheme. The values of residuals in the convergence conditions are less than 1×10-6.

33
5.6 Verification of the Numerical Procedure
• Average f can be calculated using the Darcy formula[1] :

2 ∙ Δ𝑃 ∙ 𝐷
𝑓=
𝜌𝑢2

• Average Nusselt number can be calculated[1]:

𝑞∙𝐷
𝑁𝑢 =
(𝑇𝑤 − 𝑇𝑓 )

• For forced convection heat transfer in smooth circular tubes, the resistance coefficient
f can be calculated using the Filonenko formula[2]
−2
𝑓 = ((1.82 ∗ ln 𝑅𝑒) − 1.64)
• Nusselt number is calculated by using Gnielinski formula[3]:
𝑁𝑢 = 0.012 ∗ Pr 0.4 (𝑅𝑒 0.87 − 280)
0.005 0.00484
Calculated values
0.005
Filonenko
0.00425 0.00386
Friction factor

0.004

0.004 0.00363 0.00333

0.00314
0.00326 0.00300
0.00289 0.00281
0.003
0.00289
0.00266
0.003 0.00249
0.00238
0.002
0 20000 40000 60000 80000
Reynolds number

500 Calculated values

450 Gnielinski 434.6
400 379.2 419.5
350 321.3 370.9
Nusselt number

300 270.6
322.6
250 218.5
264.5
200 158.5
150 204.4
85.7
100 141.6
50
74.4
0
0 20000 40000 60000 80000
Reynolds number
Fig 5.4 Comparison between the calculated value and the theoretical value in smooth tubes. (A) f (B) Nu.

34
The calculated values of f and Nu are compared with the values of the Filonenko formula and
Gnielinski formula, respectively. The calculated value of f & Nu is in good agreement with the
calculated value. The maximum error between the calculated value and the theoretical value of
the resistance coefficient is 15%. The maximum error between the calculated value and the
theoretical value of the Nusselt number is 13.13%.

Table 5.2 Heat transfer Surface Area of grooved tubes

5.7 Results
Numerical simulations are performed to study the thermal performance enhancement for a
range of geometrical configurations with different number of grooves, helical angles, groove
depths & groove widths. Nusselt number and friction factor are calculated with 4, 5 & 6
grooves, each at 20°, 30°, 40° & 50° helix angles, and the groove depth and groove width are
fixed 1 mm & 2mm. Nu and f are calculated at widths of 1.5, 2 & 2.5 mm and a depth of 1
mm each at 20°, 30°, 40° & 50° helix angles. Nu and f are calculated at depths of 0.75, 1 &
1.25 mm and a width of 2 mm each at 20°, 30°, 40° & 50° helix angles.

35
5.7.1 Effect of Number of grooves and Helix angle

Fig 5.5 The effect of the number of grooves on the Nu and f at different helix angles. (A) Nu. (B) f.

The groove depth and groove width are fixed 1 mm & 2mm, and the number of grooves are
4, 5 & 6 respectively. Nusselt number and friction factor increase with the increase of the
number of grooves and Nusselt number and friction factor decrease with the increase of helical
angle. As the helical angle increases, area exposed for heat transfer decreases and , the Nusselt
number increases with decrease in helix angle. In grooves, because of sharp sides, high shear
stress is generated and heat transfer convection is high. As helix angle increases from 20° to
50°, lesser number of grooves and less blockage to the flow, as a result friction factor decreases.

Fig 5.6 The Temperature & velocity cloud diagram with groove numbers. (A) N = 4. (B) N =5. (C) N = 6.

36
5.7.2 Effect of groove width
The number of grooves are 5, the fixed groove depth is 1 mm, and groove width is 1.5, 2, 2.5
mm respectively. As groove width increases from 1.5mm to 2.5mm , the surface area of groove
increases and therefore heat transfer between pipe and fluid increases, as a result Nusselt
number increases and the obstruction to fluid flow also increases with groove width, so friction
factor increases.

Fig 5.7 The effect of the groove width on the Nu and f at different helix angles. (A) Nu. (B) f.

Fig 5.8 The cloud picture of velocity & temperature with groove width. (A)w = 1.5 mm (B) 2 mm (C) 2.5 mm

37
5.7.3 Effect of groove depth
The grooves are fixed at 5, the fixed width of groove is 2 mm, and groove depths are 0.75, 1,
1.25 mm respectively. Nusselt number increases with increase of groove depth as it increases
the heat transfer area on inner surface of pipe. Friction factor increase with groove depth,
because as groove depth increases, the fluid interaction with wall increases and encounters
more obstruction with increasing groove depth.

Fig 5.9 The effect of the groove depth on the Nu and f at different helix angles. (A) Nu. (B) f

Fig 5.10 The cloud picture of velocity and temperature with different groove depths. (A) d = 0.75 mm. (B) d = 1
mm. (C) d = 1.25 mm.

38
5.8 Thermal Performance factor
The effectiveness of a heat transfer enhancement technique is evaluated by the Thermal
Performance Factor which is a ratio of the change in the Nusselt number to change in friction
factor.

Thermal Performance factor = (Nu⁄Nu )⁄(f⁄ )

s fs

Fig5.11 Variation of Thermal performance factor with Helix angle

Thermal Performance is highest for the helix angle of 40°. Thermal performance increases
with the number of grooves, its highest for 6 and least for 4.

Fig 5.12 Variation of Thermal performance factor with a)Depth of groove b) Width of groove
Thermal performance factor is highest for the helix angle of 40° and is least for 20°. Thermal
performance factor is almost constant with the variation in depth of groove. Thermal
performance factor increases with the width of groove. Pipe with 6 grooves and helix angle of
40° has the highest thermal performance factor.
39
References
1. Filonenko, G. K. (1954). Hydraulic resistance in pipes. Teploenergetika 1, 40–44.
2. Gnielinski, V. (1975). New Equations for Heat and Mass Transfer in the Turbulent
Flow in Pipes and Channels. NASA STI/Recon Technical Report A, 75.
3. Dawid Taler, and Jan Taler. Simple heat transfer correlations for turbulent tube flow.

40
 CHAPTER

6
CONCLUSIONS

In this study, ANSYS FLUENT software is used to simulate the flow and heat transfer
characteristics in helically grooved tube and study the influence of various geometric
parameters. The number of grooves are varied from 4 to 6, groove width is varied from 1.5 mm
to 2.5 mm, groove depth is varied is varied from 0.75 to 1.25 mm and the helix angle is varied
from 20° to 50° and the operating conditions is at a Reynolds number of 11250. Nusselt number
and friction factors are calculated for 28 different geometric configurations and compared to
smooth pipe and their thermal performance factor is calculated.

The conclusions are as follows

1. When the helix angle is increased from 20° to 50°, both the Nusselt number and friction
factor is increasing.
2. Compared to groove number, groove width has a greater influence on flow and heat
transfer of internally grooved tubes.
3. Groove depth has no significant effect on the flow and heat transfer, the Nusselt number
and friction factor variation is less compared to other groove geometry variation.
4. Compared to all groove geometric parameters, helix angle has the largest influence on
the flow and heat transfer characteristic in helically grooved tubes.
5. Thermal performance doesn’t vary much with variation of groove depth.
6. Thermal performance increases with increase in helix angle and start decreasing after
40°.
7. Maximum thermal performance is found at a helix angle of 40°, number of grooves is
6 and when groove width is 2.5 mm and groove depth of 0.75 mm.

41
8. The ideal configuration based on our study is geometric configuration with helix angle
of 40°, width of 2.5mm and depth of 0.75mm and no.of grooves to be 6.

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