Lecture 5-1 Double Pipe HE
Lecture 5-1 Double Pipe HE
(ChEg3115)
Lecture 5- HEDM & Calculation: Double Pipe Heat Exchanger Design (DPHED)
Effective length means the distance in each leg over which heat transfer occurs and
excludes inner pipe protruding (extend) beyond the exchanger section.
For fluid in pipes and tubes, Sieder and Tate made a correlation for both heating and
cooling fluids, principally petroleum fractions, in horizontal and vertical tube.
GD
For streamline flow where Re= <2,100
μ
1
1/3
hiD DG D 3
4wc
cμ/k μ/μw μ/μw
0.14 0.14
=1.86 =1.86 ....... 1
k μ L πkL
Where Re is Reynold number, μ𝑤 is the viscosity at the tube wall temperature and μ is the
viscosity at caloric temperature and L is the total length of the heat transfer path before
mixing occur.
05/27/2021 By- Tesfa Nega (M.Sc.) 7
Design of Double Pipe Heat Exchanger
The above equation (Eq. 1) gave maximum mean deviation of approximately ±12% from
Re=100 to Re=21,000 except for water.
Beyond the transition range, the data may be extended to turbulent flow where
GD
Re= >10,000
μ
hiD DG
0.5
1
c / k 3 / w
0.14
=0.027 .............. 2
k
The above equation (Eq.2) gave maximum mean deviation of approximately +15% and
-10% for Re above10,000 except for water.
The above equations (Eq. 1&2) can be applicable for organic liquids, aqueous solutions, and
gases. But they are not conservative for water, and additional data for water must be given.
Coefficients calculated from tube-data correlations are actually lower and safer than
corresponding calculation on pipe data. And also there are no pipe correlation in the
literature as tube correlations.
�
� �
�
The hydraulic radius is the radius of pipe equivalent to the annulus cross section.
The hydraulic radius is obtained as the ratio of the flow area to the wetted perimeter.
05/27/2021 By- Tesfa Nega (M.Sc.) 11
Design of Double Pipe Heat Exchanger
For a fluid flowing in annulus, the flow area is (𝛱/4) (D22-D12), but the wetted
perimeter for heat transfer and pressure drop are different.
For heat transfer, the wetted perimeter is the outer circumference of the inner pipe
with diameter D1, so 𝛱D1, so
In pressure drop calculation, the friction not only results from the resistance of the
outer pipe, but is also affected by the outer surface of the inner pipe
D'e=4rh=
4*flow area
4 D2
2
D1
2
= D2-D1, ft ............... 4
frictional wetted perimeter 4 D2 +D1
Therefore, Re for the same conditions, w, G, and μ are different for heat transfer and
pressure drop since De might be above 2,100 while De’ is below 2,100.
Actually, both Re should be considered only approximations, since the sharp distinction
between streamline and turbulent flow at Re of 2,100 is not completely valid.
Fouling factor:
The overall coefficient of heat transfer required to fulfill the process conditions may be
determined from the Fourier's equation when the surface area A is known and Q and ∆t are
calculated from the process conditions.
Q
then U= . If the surface is not known U is can be obtained independently of the
Δt*A
Fourier equation from the two film coefficients. Neglecting the wall resistance.
1 1 1 hioho
= Rio +Ro = + ......... 6 or U= .........7
U hio ho hio +ho
05/27/2021 By- Tesfa Nega (M.Sc.) 15
Design of Double Pipe Heat Exchanger
When heat transfer apparatus has been in service for some time, however, dirt and scale
deposit on the inside and outer side of the pipe, adding two more resistances than were
included in the calculation of U by Eq.6
The additional resistance reduce the original value of U, and the required amount of heat
is not longer transferred by the original surface A; T2 rises above and t2 falls below the
desired outlet temperature, although hi and ho remains substantially constant.
When U has been obtained from values hio and ho and Q and ∆t are calculated from the
process conditions, the surface A required for the process can be computed. The
calculation of A known as design.
When heat transfer apparatus has been in service for some time, however, dirt and scale
deposit on the inside and outer side of the pipe, adding two more resistances than were
included in the calculation of U by Eq.6
The additional resistance reduce the original value of U, and the required amount of heat
is not longer transferred by the original surface A; T2 rises above and t2 falls below the
desired outlet temperature, although hi and ho remains substantially constant.
05/27/2021 By- Tesfa Nega (M.Sc.) 17
Design of Double Pipe Heat Exchanger
To overcome this eventuality, designing the equipment to anticipate the deposition of dirt
and scale by introducing a resistance Rd called the dirt, scale, or fouling factor or
resistance.
Let Rdi be the dirt factor for the inner pipe fluid at its inside diameter, and Rdo be the
dirt factor for the annulus fluid at out side diameter of the inner pipe.
The value of U obtained in Eq.(7) only from 1/hio and 1/ho may be considered the clean
overall coefficient designated by Uc to show that dirt has not been taken into account.
If it is desired to obtain A, hio and ho must first be calculated from eq. 1 and eq. 2 which
are independent of the extent of surface, but depend upon its form, such as the diameter and
fluid flow area.
Uc will remain constant if the scale or dirt deposit does not alter the mass velocity by
constructing the fluid flow area.
1. To protect the heat exchanger from delivering less than required process heat
load for specific period
The pressure drop allowance in an exchanger is the static fluid pressure which
may be expanded to drive the fluid through the exchanger.
The pump selected for circulation of a process fluid is one which develop
sufficient head at desired capacity to overcome the frictional losses caused by
connecting piping, fittings, control regulators and the pressure drop in the
exchanger itself.
The allowable pressure drop ranging from 5 to 10 psi for an exchanger or battery
of exchangers
05/27/2021 fulfilling a single process
By- Tesfaservice except where the flow is gravity.
Nega (M.Sc.) 24
Design of Double Pipe Heat Exchanger
For gravity the allowable pressure drop is determined by the elevation of the storage
vessel above the outlet Z in the feet of fluid.
The feet of fluid may be converted to pounds per square inch by multiplying z by ρ/144
z*ρ 2
i.e. Z = , Ib/in (psi)
144
The pressure drop in pipe can be computed from Fanning equation, an appropriate
value of f which is depending on the type of flow.
F = 4 fG 2 L 2 g 2 D , Fanning equation ................... 14
The pressure drop computed by eq.14. does not include the pressure drop encountered
when the fluid enters or leaves.
For the inner pipe of the double pipe heat exchanger connected in series, the entrance
loss is usually negligible, but for annuli it may be significant.
If the velocity is not well above 3fps, the entrance and exit losses may be neglected.
05/27/2021 By- Tesfa Nega (M.Sc.) 26
Design of Double Pipe Heat Exchanger
The Calculation Of Double Pipe Exchanger:
All the equations developed previously will be combined to outline the solution of
double pipe exchanger.
Allowing a reasonable fouling resistance, a value of UD is calculated from which the surface
can be found with the use of Fourier equation Q=UDA𝛥t
Usually the first problem is to determine which fluid should be placed in the annulus and which
in the inner pipe. This depend on the relative size of flow areas for both stream.
By Tesfa Nega
Design of Double Pipe Heat Exchanger
A convenient order of calculation follows:
1. Heat balance
From T1, T2, t1,t2 check the heat balance, Q , using c at Taverage
and taverage
Q=WC(T1-T2) = wc(t2-t1)
Where W and w are flowrates, C and c are specific heat capacity
Radiation losses from the heat exchanger are usually insignificant compared with
the heat load transfer in the exchanger.
2. LMTD (counter flow)
Δt2-Δt1
LMTD=
Δt2
ln
Δt1
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Design of Double Pipe Heat Exchanger
3. Caloric temperature (Tc and tc)
If neither of the fluid is very viscous at the cold terminal, say not more than 1.0
centipoise, if the temperature ranges ((T1-T2) or (t2-t1)) do not exceed 50-1000F, and if the
temperature difference (for counter current flow (T1- t2) and (T2-t1)) is less than 500F, the
arithmetic means of T1 and T2 and t1 and t2 may be used in place of Tc and t c for
evaluating the physical properties. So you need to check all these.
And also for non-viscous fluids ɸ = (μ/μw) 0.14 may be assumed as 1.0.
Check from table which flow area is greater for the a given double pipe standard. Place
the larger stream in the inner pipe or annulus by comparing their flow area which is
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highest.
Inner pipe
Design of Double Pipe Heat Exchanger
πD 2
4. Flow area, ap= , ft 2
4
6. Obtain μ from Figure 14 at Tc or t c depending upon which the flows through the
inner pipe. μ Ib/ft.hr=centipoise *2.42. From D (ft), G ( Ib
/ ft 2 ), and μ (Ib/ft.hr) obtain
. hr
GpD
the Reynolds number, Rep=
μ 1
hiD
c / k / w
0.14
7. From Fig. 24 in which j H= 3 vs DGp/ obtain jH
k
𝑝
8. At Tc or t c obtain c (from Figure 2), μ (from Figure 14 ) and k (from Table 4) and
compute cμ/k
1/3
�
9. To obtain hi multiply jH by �
k 1
hiD 1
k 1
c c / k / w c / k
� 0.14
/ k� 3 1 or 3
3 *1 hi
D � k
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D
�
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Design of Double Pipe Heat Exchanger
Inner pipe
10. Convert hi to hio, hio =hi (Ai/A)=hi *ID/OD
Annulus
4’. Flow area, π D2 2 D12 , ft 2
aa=
4
Equivalent diameter De=
4*flow area
D 2
2
D12 , ft
wetted perimeter D1
5’. Mass velocity, w
Ga= , Ib/ft 2 .hr
aa
6’. Obtain μ from Figure 14 at Tc or t c depending upon which the flows through the annulus.
μ Ib/ft.hr=centipoise *2.42. From De
𝑝 (ft), G (
Ib / ft 2 . hr ), and μ (Ib/ft.hr) obtain the Reynolds
number, GaDe
Rea=
μ �
1
7’. From Fig. 24 obtain jH in which hoDe �
c / k / w
0.14
jH= 3 vs DeGa/
� k
��
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Annulus
Design of Double Pipe Heat Exchanger
8’. At Tc or t c obtain c (from Figure 2), μ (from Figure 14 ) and k (from Table 4)and
compute cμ/k
1/3
The value of A correspond to UD rather than Uc provides the basis on which equipment is
ultimately built. If the length should not correspond to an integral number of hairpins, a
change in dirt factor will result. The recalculated dirt factor should equal or exceed the
required dirt factor by using the next larger integral number of hairpins.
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Design of Double Pipe Heat Exchanger
14. From Table 11, obtain external surface per foot length for IPS standard pipe.
surface required
Required length =
external surface per foot length
Calculation of ∆p. this requires a knowledge of the total length of path satisfying the heat
transfer requirement.
Inner pipe,
FP = 4 fG 2 L 2 g 2 D , ft
2. FpP / 144 Pp , psi By Tesfa Nega
Design of Double Pipe Heat Exchanger
Annulus ,
4 D2 2 D12 =D
(1’). Obtain De’ D'e= 4 (D1 +D2)
2 - D1, ft
GaD'e
(2). Compute the fractional Reynolds number, R'ea=
μ
16
For Rea’ obtain f from f
De '* G /
for la min ar flow or
0.264
f 0.0035 for turbulent flow
De '* G /
0.42
(2’). Fa = 4 fG 2
L 2 g 2
D ' e, ft
(3’). Entrance and exit losses, one velocity head per hairpin:
V2
ΔFI = ,ft/hairpin
2g
ΔFa + ΔFI =ΔPa , psi
144
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Example 6.1. Double Pipe Benzene-Toluene Exchanger. It is desired
to heat 9820 lb/hr of cold benzene from 80 to 120°F using hot toluene
which is cooled from 160 to 100°F. The specific gravities at 88°F are
0.88 and 0.87, respectively. The other fluid properties will be found in
the Appendix. A fouling factor of 0.001 should be provided for each
stream, and the allowable pressure drop on each stream is 10.0 psi. A
number of 20-ft hairpins of 2- by 11/4-in. IPS pipe are available. How
many hairpins are required?
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How can analysis the heat load if the pressure drop exceed from the permissible?
Use by-pass: only three-quarters or two-thirds of the fluid flows through the exchanger
and the remainder through the by-pass. This does not provide an ideal solution, since
the reduced flow causes several unfavorable changes in the design.
The reduced flow through the exchanger reduce the mass velocity and film coefficient.
If less liquid circulates through the annulus, it has to be cooled over a long range than
from the expected.
Decrease Uc and LMTD, increase the number of hairpins greatly even though the heat
load is constant
Divide the stream (the larger stream may be divided into three, four, six parallel stream)
with series- parallel arrangement
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How can analysis the heat load if the pressure drop exceed from the allowable?
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How can analysis the heat load if the pressure drop exceed from the allowable?
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Exchanger with viscosity correction,
When the pipe wall temperature differ appreciably from the caloric temperature of the
0.14
μ
controlling fluid and the controlling fluid is viscous; the actual value of Φ = μw
must be taken into account.
To include the correction, tw, may be determined by eq 15 or 16 from uncorrected value of
ho /
and
a hio/,pwhich are then corrected accordingly by multiplication by and
a
p
respectively.
The corrected coefficients where 1are
ho= ho/a *a hioho
Uc=
hio +ho
hio = hio/p * p
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Exchanger with viscosity correction
when the cold fluid is inside in the pipe
ho/a
tw = tc + (T c -tc) ......... (15)
ho/a +hio/ p
hio/a
tw = T c - (Tc -tc) ......... (16)
ho/a +hio/p