www.ierjournal.

org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

Enhancement in the Performance of

ISSN 2395-1621
Heat Exchanger by Inserting Twisted
Tape Turbulators
#1
D.S. Nakate,#2 S.V. Channapattana,#3 Ravi.H.C
1
ameetnakate@gmail.com
2
svchanna@yahoo.co.in.
3
ravi.honnebagera@gmail.com

#1
PG Student, Department of Mechanical Engineering, Dr. D Y Patil School of Engineering
Academy, ambi, savitribai phule pune university, MH, India.
#2
Professor, Department of Mechanical Engineering, Rajarshi Shahu College of Engineering
Pune savitribai phule pune university, MH, India.
#3
Assistant Professor, Department of Mechanical Engineering, Dr. D Y Patil School of
Engineering Academy ambi, savitribai phule pune university, MH, India.

ABSTRACT ARTICLE INFO

Article History
Enhancing heat transfer surfaces are used in many engineering applications such as
heat exchanger, air conditioning, chemical reactor and refrigeration systems, hence Received :18th November
many techniques have been investigated on enhancement of heat transfer rate and 2015
decrease the size and cost of the involving equipment especially in heat exchangers. One
Received in revised form :
of the most important techniques used are passive heat transfer technique. These
techniques when adopted in Heat exchanger proved that the overall thermal 19th November 2015
performance was improved significantly. This experimental works can be taken by
Accepted : 21st November ,
researchers on Augmentation Technique such as Twisted Tape. So, Researchers tried to
2015
increase the effective surface area Contact with fluid to increases the heat transfer rate
in the heat exchanger. We tried to enhance the Heat transfer rate with the help of Published online :
Twisted Tape insert with Turbulator’s and find out the effect of Turbulator’s on Flow
of Fluid. In case of twisted tape with modified geometry, more turbulence is created 22nd November 2015
during the swirl of fluid and gives higher heat transfer rate compared to plain twisted
tape and modified twisted tape. The result shows that for modified twisted tape
geometry, the heat transfer rate is higher with reasonable friction factor for both
laminar and turbulent flow.

Keywords— Augmentation, friction factor, Heat Exchanger, Tube, Turbulators,

Twisted Tape, Vortex

conversion, utilization & recovery of thermal energy in

I. INTRODUCTION
Heat exchangers are devices that can be used to transfer
heat from a fluid stream (liquid or gas) to another fluid at
different temperatures. Heat Exchanger is a device in which
the exchange of energy takes place between two fluids at
different temperature. A heat exchanger utilizes the fact that,
where ever there is a temperature difference, flow of energy
occurs. So, that heat will flow from higher temperature heat
reservoir to the lower temperature heat reservoir. The
flowing fluids provide the necessary temperature difference
and thus force the energy to flow between them. Heat
exchangers are used in different processes ranging from
various industrial, commercial & domestic applications.
These include power production, process, chemical and food
industries, electronics, environmental engineering, and
waste heat recovery, manufacturing industries and air
conditioning, refrigeration and space applications. Examples
of heat exchangers that can be found in all homes are
heating radiators, the coils on your Refrigerator and room
air conditioner and the hot water tank. The development of
high performance thermal systems has stimulated interest in
methods to improve heat transfer. The study of improved
heat transfer is referred to as heat transfer enhancement,
augmentation or intensification. The performance of
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

conventional heat exchanger can be substantially improved Inner pipe OD=25mm

by a number of enhancement techniques. A great deal of Outer pipe ID =53mm
research effort has been devoted to developing apparatus Outer pipe OD =61mm
and performing experiments to define the conditions under Material of construction= Copper
which an enhancement technique will improve heat transfer. Heat transfer length= 2.43m
Heat transfer enhancement technology has been widely Pressure tapping to pressure tapping length = 2.825m
applied to heat exchanger applications in refrigeration, Water at room temperature was allowed to flow through the
automobile, process industries etc. The goal of enhanced inner pipe while hot water (set point 60°C) flowed through
heat transfer is to encourage or accommodate high heat the annulus side in the counter current direction.
fluxes.This result in reduction of heat exchanger size, which
generally leads to less capital cost. Another advantage is the III. TYPES OF INSERTS USED
reduction of temperature driving force, which reduces the
For experimentation, three types of twisted tape inserts
entropy generation and increases the second law efficiency.
made from stainless steel strips of thickness 1.80 mm were
In addition, the heat transfer enhancement enables heat
used.
exchangers to operate at smaller velocity, but still achieve
the same or even higher heat transfer coefficient. This 1. Reduced Width Twisted Tape(RWTT):
means that a reduction of pressure drop, corresponding to Twisted tapes of width 16mm, thickness
less operating cost, may be achieved. All these advantages 1.80 mm were used in the inner pipe of ID
have made heat transfer enhancement technology attractive 22mm as shown in fig 2.
in heat exchanger applications. For shell and tube heat
exchangers, the tube insert technology is one of the most
common heat transfer enhancement technologies,
particularly for the retrofit situation. With tube insert
technology, additional exchangers can often be avoided and
thus significant cost saving becomes possible.
Furthermore as a heat exchanger becomes older, the
resistance to heat transfer increases owing to fouling or
scaling. These problems are more common for heat
exchangers used in chemical industries and marine
applications. In this case the heat transfer rate can be
improved by introducing a disturbance in the fluid flow by
different enhancement technologies (breaking the viscous
and thermal boundary layer). In this projects, a review of
heat transfer enhancement tool i.e. Inserting Twisted Tape
Turbulators is done, for laminar and turbulent flow. Since it
is most commonly used enhancement tool.
Fig 2. Reduced Width Twisted Tape (RWTT)
2. Baffled Reduced Width Twisted Tape (BRWTT1):
Baffles in the shape of rectangular strips of size
16mm×10mm×1.80mm were attached in such a
way that they were projecting at right angles on
each side to the surface of twisted tape. A constant
distance of 20 cm was kept in between two
consecutive strips as shown in fig 3.

Fig 1.Schematic diagram of Experimental Setup

II. EXPERIMENTAL SETUP

THE EXPERIMENTAL STUDY IS DONE IN A DOUBLE PIPE
HEAT EXCHANGER HAVING THE SPECIFICATIONS AS LISTED
BELOW:-
Specifications of Heat Exchanger:
Inner pipe ID = 22mm
 www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

manometer at room temperature.

3. Preparation of Wilson chart:
(1)
Where Rd is the dirt resistance
all the resistance, excepts the first term on the RHS of
equation (1) are constant for this set of experiments.
For Re > 1000, seider tate equation for smooth tube is
of the form :
there fore equation can be written as
(2)
Where k is constant And it is found to be from the
Wilson chart ( as the intercept on the y-axis
K =6.613 ×
After confirmation of validity of experimental values
of friction factor and heat transfer coefficient
in smooth tube with standard equations, friction factor and
heat transfer studies with inserts were conducted.
Fig 3. Baffled Reduced Width Twisted Tape (BRWTT1 )
Standard equations:-
3. Baffled Reduced Width Twisted Tape with holes I. Friction factor (fo) calculations:
(BRWTT2): In these twisted tapes, holes of
diameter 6 mm were drilled at midpoint of two For Re ˂ 2100
consecutive strips of BRWTT1 as shown in fig 4. f=
(3)
For Re ˃ 2100
f= (4)
II. Heat transfer calculations

i) Laminar Flow:
For Re < 2100

Nu= f(Gz)

Where Gz =
(5)
For Gz<100, Hausen Equation is used.

(6)
Fig 4 Baffled Reduced Width Twisted Tape with holes (BRWTT2)
For Gz>100, Seider Tate equation is used

4. The present work deals with finding the friction factor and
(7)
the heat transfer coefficient for the various types of twisted
tapes with twist ratios (yw=3.69, 4.39, 5.25) and comparing
III. Transition Zone:
those results with that of smooth tube and finally
For 2100<Re<10000, Hausen equation is used.
finding the heat transfer enhancement in comparison to a
smooth tube on constant flow rate basis (R1 ) as well as ( ) ( )
constant pumping basis (R3)
(8)

IV. EXPERIMENTAL PROCEDURE IV. Turbulent Zone:

1. Twist Ratio(y) of the twisted tapes were calculated. (9)

Twist Ratio, yw = H/W Where H = Linear distance Viscosity correction Factor is assumed to be equal
of the tape for 180° rotation, W = Width of
to 1 for all calculations as this value for water in present
twisted tape.
case will be very close to 1 & the data for wall temperatures
2. For friction factor determination: Pressure drop is
is not measured.
measured for each flow rate with the help of
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

Sample calculation:

1. PRESSURE DROP & FRICTION FACTOR

CALULATIONS:
For BRWTT1 having yw=3.69
m=0.2090 Kg/sec
Experimental friction factor
Area A= = =3.8 10-04 m2
m/sec
Fig.6. Temperature in different RTDs

ΔT1 = T4 - T1 = (49.1-38.5) =10.5

= (1603-1000) ΔT2 = T3 – T2 = (51.0-41.1) ) =9.9
= 4916 n/m2 Δ Δ
LMTD = Δ
fa = = Δ
-3
=63.29
Q1 = mc × Cpc × (T2 - T1) =0.2090 ×4187 × (41.1- 38.5)
= 2275W
For viscosity calculation: Q2 = mh × Cph × (T3 - T4) =0.2715×4187× (51.0-49.1)
= 2160W
Heat balance error =
Qavg = (Q1+Q2)/2 = (2275+2160)/2 =2218 W
Heat transfer Area, Ai = = 0.022 2.43
=0.1860 m2
( ) =1289 w/

=18089
hi can be calculated using Eq.1

(11)
Fig 5. Viscosity vs. Temperature Ha = 8721 W/m2 °C
Theoretical Calculation for smooth tube
4×10-11T4-9×10-9T3+9×10-7T2-5×10-5T+0.0017
(10)
Theoretical friction factor calculation for smooth tube:

(12)
= 17218
Fo = 0.046 = 0.046 = 6.54 10-3 For Prandtl Number calculation:

HEAT TRANSFER COEFFICIENT CALCULATION:

For BRWTT1 having yw=3.69
mc= 0.209 kg/sec (750lph) & mh=0.2715kg/sec
T1 = 38.5
T2 =41.1
T3 =51
T4 =49.1

Fig 6. Prandtl Number vs. Temperature

3×10-7T4-8×10-5T3+0.0072×10-7T2-0.387T+11.995
(13)
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

Pr (at T=Tavg) =3.695

ho (hi for smooth):
ho =
ho=2601 w/
R1= =8721/2601=3.35
To calculate fa at Re =18089, use correlation for fa
vs.Re for BRWTT1 having Yw=3.69
Fa = 0.9409
=0.06226 Fig.7. Friction factor vs. Reynolds number for Smooth tube, RWTT,
BRWTT1 & BRWTT2
For equal pumping power,
Fig.8. shows the variation of fa/fo with Reynolds number
(14) for RRWTT, BRWTT1 &BRWTT2.
Axo = = =3.8 10-04 m2 1. fa/fo increases with decrease in twist ratio due to increase
Axa= = in swirl flow created with decreasing twist ratio.
2. fa/fo is found to be maximum for BRWTT2 (8.86-14.44)
=3.48 10-04 m2
followed by BRWTT1 (7.79-11.23) followed by RWTT
(3.23-5.96) because degree of turbulence decreases in the
same order.
Reo = 39341
ho at Reo(Equivalent Reynolds number in the smooth tube
for same pumping power) Fig.9. shows the correlations for friction factor for different
twisted tapes for RRWTT, BRWTT1 & BRWTT2. These
1) ho = correlations were used while calculating performance
evaluation criteria3.

2) ho =
ho = 4843 W/m2 °C
R3 = = 1.80
V.RESULTS & DISCUSSION

Fig.7. shows the variation of friction factor (fa) with

Reynolds Number for Smooth tube, Reduced width twisted
tape (RWTT), Baffled Reduced width twisted tape
(BRWTT1), Baffled Reduced width twisted tape with holes
(BRWTT2) for different twist ratios (yw=3.69,yw=4.39,
yw=5.25). As the twist ratio decreases, a higher degree of
swirl is created which leads to higher pressure drop & hence
higher friction factor. In case of BRWTT1 & BRWTT2, a
much higher friction factor is observed because of increase
Fig.9. Correlations for variation of Friction factor with Reynolds Number
in degree of turbulence created by the respective tapes.
HEAT TRANSFER COEFFICIENT RESULTS:
Fig.10. shows the variation of heat transfer coefficient (ha)
with Reynolds Number for Smooth tube, Reduced width
twisted tape (RWTT), Baffled Reduced width twisted tape
(BRWTT1), Baffled Reduced width twisted tape with holes
(BRWTT2) for different twist ratios (yw=3.69, yw=4.39,
yw=5.25). As the twist ratio decreases, a higher degree of
swirl is created which increases turbulence & hence the heat
transfer coefficient increases as the twist ratio decreases. In
case of BRWTT1 & BRWTT2, a much higher heat transfer
coefficient is observed because of increase in degree of
secondary flow created which disturbs the entire thermal
boundary layer & hence the heat transfer coefficient
increases as the twist ratio decreases.
Fig. 8. fa/fo vs. Reynolds Number for RRWTT, BRWTT1 & BRWTT2
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

Fig.11. Performance evaluation criteria, R3 vs. Reynolds Number for

RWTT, BRWTT1, BRWTT2
VI.CONCLUSION
Experimental investigations have been carried out to
examine the effect of RWTT, BRWTT 1, BRWTT2 With
different twist ratio within the pipe. Depending on the
analysis of the result the following conclusion can be carried
out.
I. For same twist ratio, Baffled reduced width
twisted tape with holes & Baffled reduced
width twisted tape shows higher heat
transfer coefficient & friction factor
increase because of higher degree of
turbulence created.
II. For same twist ratio, Baffled reduced width
Fig.10. Heat transfer coefficient vs. Reynolds Number for Smooth tube, twisted tape with holes & Baffled reduced
RWTT, BRWTT1 & BRWTT2 width twisted tape gives higher heat
transfer coefficient than the reduced
Plot for Performance evaluation criteria, R1 (based on width twisted tapes.
constant flow rate) vs. Reynolds number for different tapes III. The correlations derived from friction
is shown in Fig.11. factor values have R2 (Correlation
coefficient) values very close to 1. So, the
correlations can be used for finding friction
factor values for respective designs in the
given range of Reynolds number.
IV. On the basis of performance evaluation
criterion R3, twisted tapes-BRWTT 1 &
BRWTT2 with yw = 3.9 were found to be
the augmentations.
Further studies can be done using this study as base.
Some of the possibilities are mentioned below:
I. Experimental work can be done at low
Reynolds number using viscous liquids, as
the tapes have shown comparatively better
results at low Reynolds number
II.
istance between two consecutive baffles & holes
Fig.11. Performance evaluation criteria, R1 vs. Reynolds Number for
RWTT, BRWTT1, BRWTT2 can be varied to see their effect on heat transfer &
Plot for Performance evaluation criteria, R3 (based on friction factor.
constant pressure drop) vs. Reynolds number for different III.
tapes is shown in Fig.12. For obtaining R3, correlation eometry of baffles:
between friction factor & Reynolds Number for respective
tape is used.  Circular baffles instead of rectangular baffles can
be used.
 Baffles can be kept at an angle to flow of liquid
instead of putting them perpendicular to flow of
liquid.
 Size of baffles can be varied.
 The proposed designs can be used for cooling of
liquids

NOMENCLATURE

Ai Heat transfer area, m2

Axa Cross- section area of tube with twisted tape, m2
Axo Cross-section area of tube,
Cp Specific heat of fluid, J/Kg.K
di ID of inside tube, m
do OD of inside tube, m
f Fanning friction factor, Dimensionless Friction
factor
fa for the tube with inserts, Dimensionless
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 2 Page 1563-1570, 2015, ISSN 2395-1621

f0 Theoretical friction factor for smooth [2].Jagpreet Singh, Ashwani Kumar, Satbir Singh Sehgal,
tube,Dimensionless Experimental Studies on Heat Transfer Augmentation of
g acceleration due to gravity, m/s2 a Heat Exchanger with Swirl Generators Inserts,
Gz Graetz Number, Dimensionless International Journal of Emerging Science and
h Heat transfer coefficient, W/m2 °C Engineering (IJESE), ISSN: 2319–6378, Volume-2,
ha Heat transfer coefficient for tube with Issue-6, April 2014.
inserts,W/m2 °C
ho Heat transfer coefficient for smooth tube, W/m2 °C [3].P.K.Nagarajan, Nitesh Mittal, Rohit Chechani,
hi(exp) Experimental Heat transfer coefficient, W/m2 °C Experimental studies on heat transfer and friction factor
hi(thero) Theoretical Heat transfer coefficient, W/m2 °C characteristics of parabolic trough solar water heating
H Pitch of twisted tape for 180°rotation, system with and without twisted tapes, Proceedings of
L heat exchanger length, m the 37th National & 4th International Conference on
LMTD Log mean temperature difference, °C Fluid Mechanics and Fluid Power, December 16-18,
m Mass flow rate, kg/sec 2010, IIT Madras, Chennai, India.
Nu Nusselt Number, Dimensionless [4].Anil Singh Yadav, Effect of Half Length Twisted-
Pr Prandtl number, dimensionless Tape Turbulators on Heat Transfer and Pressure Drop
Q Heat transfer rate, W Characteristics inside a Double Pipe U-Bend Heat
Re Reynolds Number, Dimensionless Exchanger, Jordan Journal of Mechanical and Industrial
R1 Performance evaluation criteria based on constant Engineering, Volume 3, Number 1, March. 2009, ISSN
flow rate, Dimensionless 1995-6665, Pages 17- 22.
R3 Performance evaluation criteria based on constant
pumping power, Dimensionless [5]. MaheshkumarJ.Patel, K.S.Parmar, U. R. Soni,
Ui Overall heat transfer coefficient based on inside Improve the Performance of Heat Exchanger: Twisted
surface area, W/m2 °C Tape Insert With Metallic Wiry Sponge, International
v flow velocity, m/s2 Journal on Recent and Innovation Trends in Computing
W Width of twisted tape, m and Communication, Volume: 2 Issue: 4, ISSN: 2321-
w Width ratio (w/di) Dimensionless 8169, 850 – 853.
yw Twist ratio of twisted tape (H/W), Dimensionless
[6].Watcharin Noothong, Smith Eiamsa-ard, Effect of
Greek letters Twisted-tape Inserts on Heat Transfer in a Tube, The
2nd Joint International Conference on “Sustainable
∆h Height difference in manometer, m Energy and Environment (SEE 2006)”, 21-23 November
∆P Pressure difference across heat exchanger, N/m2 2006, Bangkok, Thailand.
µ Viscosity of the fluid, N s/m2
[7]. C.Nithiyesh Kumar, P.Murugesan, Review On
µb Viscosity of fluid at bulk temperature, N s/m2
Twisted Tapes Heat Transfer Enhancement,
µw Viscosity of fluid at wall temperature, N s/m2
International Journal Of Scientific & Engineering
δ Density of the fluid, kg/m3
Research, Volume 3, Issue 4 April-2012, ISSN 2229-
ACKNOWLEDGMENT 5518.
I wish to express my sincere gratitude to Dr. V. N. [8] S.D.Patil, Analaysis of twisted tape with winglets to
NITNAWARE, Principal and Prof. A.A. Bagade H.O.D of improve the thermo hydraulic performance of tube in
Mechanical Engineering Department, of Dr. D.Y.Patil tube heat exchanger, International journal of advanced
School Of Engineering Academy, Ambi for providing me an engineering research and studies E-ISSN 2249-8947.
opportunity to present a paper on “Enhancement in the
Performance of Heat Exchanger by Inserting Twisted [9].Bodius Salam, Heat transfer enhancement in a tube
Tape Turbulators .” This Paper is incomplete without the using twisted tape insert, Proceedings of the 13th Asian
guidance of many peoples. Congress of fluid mechanics, 17-21 Dec 2010.
I sincerely thank to my project guides Prof. S.V
[10].Sivashanmugam, P. and Suresh, S. ―Experimental
Channapattana and Prof. RAVI H.C for guidance in
studies on heat transfer and friction factor characteristics
carrying out this paper. I also wish to express my gratitude
of turbulent flow through a circular tube fitted with
to Prof. R.R. Katwate (ME Co-ordinator) who
regularly spaced helical screw tape inserts‖,
has been constantly a source of encouragement for this
Experimental Thermal and Fluid Science 31
paper work. I wish to avail myself of this opportunity,
(2007).301-308.
express a sense of gratitude and love to my friends and my
beloved parents for their manual support, strength, and help [11].Saha, S. K. and Bhunia, K. ―Heat transfer and
for everything. pressure drop characteristics of varying pitch twisted-
tape-generated laminar smooth swirl flow.‖ 4th ISHMT–
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