Heat Mass Transfer

DOI 10.1007/s00231-016-1838-x

ORIGINAL

Heat transfer augmentation in double pipe heat exchanger using

mechanical turbulators
Kushal Kamboj1 · Gurjeet Singh2 · Rohit Sharma1 · Dilbagh Panchal1 · Jaspreet Hira1 

Received: 20 August 2015 / Accepted: 13 May 2016

© Springer-Verlag Berlin Heidelberg 2016

Abstract  The work presented here focuses on heat transfer of circular cross-section 15, 10, and 5 cm at Reynolds’s
augmentation by means of divergent-convergent spring tur- number ranging between 9000 < Re < 40,000 is done
bulator (the enhancement device). Aim of the present work graphically.
is to find such an optimum pitch at which the augmenta-
tion in heat transfer is maximum and the amount of power List of symbols
consumption is minimum, so that an economic design can D Pipe diameter
be created with maximum thermal efficiency. So, the con- g Acceleration due to gravity
cept of pitch variation is introduced, which is defined as the h Heat transfer coefficient
horizontal distance between two consecutive turbulators. It hf Head loss
describes that, the lesser is the pitch the more number of K Thermal conductivity of fluid
turbulators that can be inserted in inner pipe of double pipe L Characteristics length of pipe
heat exchanger, hence more will be the friction factor. This ln Natural logarithm
physics increases convective ability of the heat transfer ṁ Mass flow rate of fluid
process from the surface of inner pipe. There is a certain Nu Local Nusselt number based on bulk tempera-
limit to which a pitch can be decreased, lesser the pitch the ture of the fluid
more the pressure drop and friction factor and hence the Nut Convective heat transfer coefficient of tube
more will be the pumping power requirement to maintain Nup  Convective heat transfer coefficient of plain
a desired mass flow rate of hot water. Analysis of thermal tube
factors such as Nusselts number, friction factor, with dif- p Pitch length/spacing
ferent pitches of divergent convergent spring turbulators P Static pressure
Pr Prandtl number
ΔP Pressure drop over length L of pipe
* Kushal Kamboj
r Pipe radius
kushhalkamboj@gmail.com
Re Reynolds number
Gurjeet Singh
Ts Surface temperature
gurjeetsingh0009@gmail.com
T∞ Bulk temperature
Rohit Sharma
T Temperature
r25sharma@gmail.com
Cp Specific heat capacity
Dilbagh Panchal
dilbagh129@gmail.com
Subscripts
Jaspreet Hira L Characteristic length of pipe
jhira@amity.edu
m Mean
1
Amity University Uttar Pradesh, Noida, India max Maximum
2
Mechanical Engineering Department, PEC University min Minimum
of Technology, Chandigarh 160012, India PT Plain tube

13

t Turbulator
Theo Theoretical
Exp. Experimental
o Outlet, outer
i Inlet, inner
a Air
w Pipe wall
Greek symbols
λ Darcy friction factor
η Thermal performance
μ Fluid viscosity
ν Kinematic viscosity
ρ Fluid density
Δ Net change in quantity
τ Shear stress
β Coefficient of thermal expansion
Abbreviations
DCST-C Divergent convergent spring turbulator-circular
DPHE Double pipe heat exchanger
LPH Liter per hour
LPM Liter per minute
RTD Resistance temperature detectors
1 Introduction
A heat exchanger is a device that is used to transfer ther-
mal energy (enthalpy) between two or more fluids, between
a solid surface and a fluid, or between solid particulates
and a fluid, at different temperatures and in thermal con-
tact. In heat exchangers, there are usually no external heat
and work interactions. Typical applications involve heat-
ing or cooling of a fluid stream of concern and evapora-
tion or condensation of single or multi-component fluid
streams. Temperature gradient is the factor facilitating
the heat transfer including a certitude that heat exchange
occurs in the direction of decreasing temperature. Heat
transfer theory explains itself by three distinctive modes of
heat transmission; radiation, conduction and convection. In
Heat exchangers radiation phenomenon does take place,
but its role is rather insignificant vis-à-vis conduction and
convection.
Tubes with rough surfaces have much higher heat trans-
fer coefficients than tubes with smooth surfaces. Therefore,
tube surfaces are often intentionally roughened, corrugated,
or finned in order to enhance the convection heat transfer
coefficient and thus the convection heat transfer rate. Heat
transfer in turbulent flow in a tube has been increased by as
much as 400 % by roughening the surface [1]. Roughening
13
Heat Mass Transfer
the surface, of course, also increases the friction factor and
thus the power requirement for the pump or the fan.
Designing a heat exchanger, which suits majority of
applications, is very difficult as well as important, as it
always has the limitation of size and fluid flow rate, result-
ing in a low heat transfer rate. The augmentation of heat
transfer is the ability to achieve high performance heat
exchangers, leads to its size reduction and high initial
investment.
So, the passive heat enhancement techniques can be
applied by installing the turbulence generators or turbula-
tors, e.g. the insertion of twisted stripes and tapes [2–13],
the insertion of coil wire [14–16] and helical wire coil in
the heat exchangers. The results of those studies show that
although heat transfer efficiencies were improved, the fric-
tion factor of pipes was considerably increased.
In recent years, thousands of numerical and experimen-
tal studies have been performed on heat transfer enhance-
ment techniques of different configuration. Mainly heat
transfer and frictional characteristics have been studied in
detail with respect to different geometrical parameters in
various ranges of Reynolds number. Further these studies
have been cross-verified with researches already performed
in this field.
It is investigated by studying various research papers
that there is a scope of design modification in heat transfer
enhancement device which can significantly affect the rate
of heat transfer and friction factor. As it is clear, twisted
tape gives better results which encourage new researchers
to further improve the design. So, in this research a new
concept inspired by the literature which is divergent con-
vergent spring turbulators of circular cross section (DCST-
C). The spring type design of DCST is influenced from
experiments performed by Kumbhar et al. [17] as heat
transfer behavior in a tube with conical wire coil inserts.
The conical shape and divergent-convergent section is
influenced from experiments performed by Eiamsa-ard
et al. [18] as enhancement of turbulent flow heat trans-
fer in a tube by using nozzle turbulators. Sufficient pitch
(as zero pitch increased the friction factor and hence the
pumping power requirements) is provided in DCST which
is analogous to experimental investigation of heat transfer
and turbulent flow friction in a tube fitted with perforated
conical-rings by Kongkaitpaiboo et al. [19].
So far no work is reported on the study of spring turbu-
lators of varying cross section, so it is a new design which
is influenced by twisted tapes and wire coil inserts. This
research work is focused upon overcoming the limitations
imposed previouslySo, the DCST-C design advantage is
that it uses less material and also expected to have higher
heat transfer rate at the cost of lesser pressure drop.
Heat Mass Transfer
Fig. 1  Block diagram of double pipe heat exchanger
2 Methodology and experimental set up
2.1 Objectives
The focus here is on the experimental, graphical analysis &
study of the effect of divergent-convergent springs having cir-
cular cross-sections, on the following factors & parameters:
1. Heat gain and heat drop
2. Friction factor,
3. Nusselt number
4. Convective heat transfer coefficient
5. Overall heat transfer coefficient
6. Nusselt number versus reynolds number for verification
of Nusselt number of plain tube
7. Ratio of friction factors of DCST and that of plain tube
versus Reynolds number.
8. Friction factor verification of plain tube.
9. Ratio of Nusselt number of DCST and that of plain tube
versus Reynolds number.
10. Mass flow rate of hot water versus heat gain and heat
drop.
11. Thermal performance factor versus Reynolds number
2.2 Assumptions
1. Flow is assumed to be steady.
2. Flow is non-uniform.
3. Flow is incompressible.
4. Isothermal conditions are maintained, though minor
heat losses are neglected.
5. Coefficient of thermal expansion on inner side and coef-
ficient of thermal contraction on outer side of inner pipe
negates each other, of concentric tube heat exchanger.
6. Inner pipe’s inner surface is assumed to be smooth.
7. Sieder-tate equation takes into account the change in
viscosity (µ and µs) due to temperature change between
the bulk fluid average temperature and the heat transfer
surface temperature, respectively. The viscosity factor
will change as the Nusselt number changes. Though
viscosity factor varies very nearly to unity, hence is
assumed to be constant.
2.3 Experimental setup
The experimental set up used in the present work is shown
in Figs. 1 and 2 and is discussed as follows:
13

Fig. 2  Photograph of double pipe heat exchanger
The setup includes a hot water tank consisting of four
heaters of capacity 2 KW each that can maintain a maxi-
mum constant temperature of 75 °C. The setup includes
two motors of capacity 1 HP for hot water and 0.5 HP
for cold water. This is so because hot water is required
to supply higher LPHs than cold water at certain specific
stages.
Test section includes two pipes; Inner pipe (smooth) of
copper, 4 m length and its U-bend is of 0.232 m length,
and outer pipe is made up of G.I. which is insulated and
is approximately equal in length to that of inner pipe.
Two well calibrated rotameters of range 0–2000 and
0–1500 LPH are used for hot water and cold water respec-
tively. Two pressure gauges are used of range 0–5 kg/cm2
with ±0.01 error.
To measure inlet and outlet temperatures of hot water
and cold water four pt-100 RTDs are used and to meas-
ure outside wall temperature of inner copper tube four
chip sensors are used and all the experimental work taken
under insulated environment. Readings of temperature
are noted down from multi-point digital temperature
indicators.
13
Heat Mass Transfer
2.4 Augmetation technique used in current work
Aim of the work was to employ divergent-convergent
turbulators (DCST) of circular (DCST-C) cross-section
as shown in Fig. 3, inside of copper tube of double pipe
heat Exchanger. DCST-C s made of high carbon spring
steel with 10 cm of free length and an external diameter of
2.1 cm. It was only sufficiently large so that it could make
an interference fit with inner tube of DPHE. These were
mounted at regular intervals on two thin cylindrical rods
with rod diameter equals to the minimum diameter or mid-
section of DCST-C. Three rods mounted with DCST-C are
inserted in the inner tube prior to attaching U-bend section
to outer tube as shown in Fig. 4a–c.
Inner tube contained hot water flow with flow rate rang-
ing from 700 to 2000 LPH and outer tube contained cold
water with flow rate varying between 500 and 1500 LPH.
Rotameters were installed to measure the flow rate, and
was controlled by flow regulating valves. As described ear-
lier this work utilized passive technique for heat transfer
enhancement, which is primarily aimed to generate a swirl/
turbulent flow.
Heat Mass Transfer
Fig. 3  Conceptual design
of DCST with flow path of
turbulator
Fig.  4  a DCST mounted on rod with Pitch = 15 cm. b DCST mounted on rod with Pitch = 10 cm. c DCST mounted on rod with Pitch = 5 cm
A number of DCST-C were mounted on a brass rod of
8 mm diameter and 200 cm of length, by brazing to elimi-
nate any undue movement of DCST-C, inserted in inner
pipe of copper and flow was initiated. Three variations in
pitch ratios were provided viz. 5, 10 and 15 cm as shown in
Fig. 4a–c. The spring pitch was kept constant in all of the
DCST-C.
As it can be observed from Fig. 4a–c that lower the pitch
results in more number of springs that can be mounted on
a single rod. The term “pitch” used throughout the paper
refers to the distance between two consecutive DCST-C
when mounted on brass rod. The concept behind varying
the pitch was that lower is the pitch the more are the DCST-
C that can be mounted on a single rod and more will be the
13

Fig. 5  Validation of Nusselt 160.000
number for plain tube with
literature 140.000
120.000
100.000
Nu
80.000
60.000
40.000
20.000
0.000
9000 14000
obstruction they will cause to hot water when inserted in
inner copper pipe and more will be the friction factor pro-
duced leading to more fluid mixing, breaking of boundary
layer, swirl production and consequently higher will be the
heat transfer.
2.5 Experimental procedure
2.5.1 Step 1: Rotameter and RTDs calibration
Two buckets of 25 L were used to collect water for 3 min
which flows through cold water and hot water side rotam-
eter (shown in Tables 1, 2). Further, four RTDs were cali-
brated by dipping in water troughs one after another and
observed readings were compared with the referenced set
by premeasured RTD value (shown in Table 3).
2.5.2 Step 2: Standardization and verification
Plain tube readings were obtained for pressure drop and
hence friction factor characteristics at normal temperature
of water. The main motive behind this study was to insert
DCST of varying pitches in inner plain tube which could
make its surface rough, and hence could alter its readings.
After obtaining sufficient amount of readings, the collected
data was compared with calculated theoretical value.
2.5.3 Step 3: Initiating and executing plain tube
experimetation
After obtaining the readings as mentioned in step-II,
260 L of water was heated to 75 °C which took approxi-
mately 1.5 h to reach this stage. Then the hot and cold
water motors were started at same LPH and steady flow
13
Heat Mass Transfer
NuExp.
NuDittus-Boelter
Equation
19000 24000 29000 34000 39000 44000
Re
was obtained in 15 min. LPH of hot water was main-
tained constant for six variations in LPH of cold water
and this procedure was obtained for a range of 500–
1500 LPH of cold water and 700–2000 LPH range of
hot water. The cold water and hot water followed coun-
ter flow directions at their respective flow rates. When
constant and stable values at temperature display panel
were obtained, then the inlet–outlet and inner wall tem-
peratures were measured. After obtaining the results
for plain tube the Nusselt number verification for plain
tube is done by comparing with results obtained from
Eq. (14).
2.5.4 Step 4: Preparing dcst for inner tube insertion
DCST of length 18 cm were mounted and brazed on 2 m
brass rods at a pitch of 15, 10 and 5 cm after wards. A pair
for each pitch set was made as shown in Fig. 4a–c. The
U-bend of pipes were given a detachable flange coupling
joint due to which it became fairly convenient to insert
DCSTs in and out. The same procedure to initiate the
experiment was followed as mentioned for plain tube. The
steady state was achieved within 20 min after insertion of
DCSTs. Friction factor and pressure drop results were col-
lected and compared with plain tube results. Same proce-
dure was followed for all DCSTs with varying pitches.
2.5.5 Step 5: Thermal performance results
and repeatability
The procedure was re-initiated for thermal performance
and repeatability check (shown in Tables 4, 5). For a con-
stant pumping power equivalent Reynolds number was cal-
culated and water was kept at 75 °C.
Heat Mass Transfer

Fig.  6  a Effect of pitch on HTE (a) 180.000

for DCST with plain tube, Pitch
P = 15, 10, 5 cm. b Effect of 160.000
pitch on HTE for DCST with
P = 5, 10 and 15 cm NuT/NuPT 140.000
versus Re
120.000

100.000

Nu
80.000

60.000
Nu Exp.
40.000
Nu Exp. p=5cm
20.000 Nu Exp. p=10cm
Nu Exp. p =15cm
0.000
9000 14000 19000 24000 29000 34000 39000 44000
Re

(b) 1.220
Nu5cm/NupT
1.200
Nu10cm/NupT

1.180 Nu15cm/NupT

1.160
NuT/NuPT

1.140

1.120

1.100

1.080

1.060

1.040
9000 14000 19000 24000 29000 34000 39000 44000
Re

2.5.6 Step 6: For heat transfer coefficient calculation
Hot water at 75 °C is allowed to pass through the inner
pipe of heat exchanger at 1000 LPH (mh  = 0.2715 kg/s).
Cold water is now allowed to pass through the outer pipe
of heat exchanger in counter current direction at 1000 LPH
(mc = 0.2715 kg/s). The inlet and outlet temperatures for both
hot water and cold water (T1–T4) are recorded only after
temperature of both the fluids attains a constant value. The
procedure was repeated for different cold water flow rates.
2.6 Data reduction
Heat exchangers with working fluid water was taken in
all of the experiments mentioned in previous section, with
parametric study of effects of Reynolds number varying from
9000 to 40,000. Aspiration behind the variation of pitch ratios
was basically to enhance the friction factor which varies in an
inverse proportion with all these parameters. But, increasing
friction factor i.e. decrease in pitch ratio or an increase in the
number of turbulators employed, puts a direct impact on pres-
sure drop and hence on the required pumping power. But, to
maintain higher levels of Reynolds number or high LPMs,
a high and constant pumping power is desired. Hence, it is
required to maintain optimum conditions such that a balance
can be created between pitch ratio, friction factor, pressure loss
and hence pumping power. Equations which form the basis of
such experimental investigation can be summed as follows.
Since Reynolds number represents the ratio of momen-
tum to viscous forces the relative magnitudes of Gr and Re

13
 Heat Mass Transfer

Fig. 7  Verification of friction 40.000

factor for plain tube
35.000

30.000

25.000

20.000

λ
15.000

10.000
λDarcy-Weisbach Friction Factor*1000
5.000
λBlasius Equation*1000
0.000
5000 10000 15000 20000 25000
Re

are an indication of the relative importance of natural and inner tube. The average heat flux from the tube wall to the
forced convection in determining heat transfer. Forced con- fluid is defined in terms of surface area.
vection effects are usually insignificant when Gr/Re2 >> 1  
and conversely natural convection effects may be neglected Q = hA(Tw − Tb ) + σ A Tw4 − Tb4 (7)
when Gr/Re2 << 1. When the ratio is of the order of one,
combined effects of natural and forced convection have to The convective heat flux is assumed to be uniformly dis-
be taken into account. tributed over the heated wall tube and can be evaluated
Grashof number [21, 22] as
gβ(Ts − T∞ )D3 Q = hA(Tw − Tb ) (8)
GrD = (1)
ν2 The averaged heat transfer coefficient, h and the mean Nus-
The steady state of the heat transfer rate is assumed to be selts number, Nu are estimated as follows Cp,a
equal to the heat loss from the test section which can be
Cp,a (To − Ti )
expressed as h= (9)
A(Tw = Tb )
Qair = Qconv (2)
hD
where, Nu = (10)
k
Qair = ṁCp,a (T0 − Ti ) (3) 2.7 Standard equations
Qconv = hA(Tw − Tb ) (4) 2.7.1 Friction factor calculations
where,  ∆P 
∗D
Darcy − Weisbach Friction Factor :  = L 2 
 
To − T i ρV
Tb = (5) 2 (11)
2

 Tw 0.316
Tw = (6) Blasius Equation:  = (12)
N Re0.25
where, N—total number of thermocouples or resistance
0.046
temperature detectors between inlet and exit of the test sec- Colburn’s Equation:  = (13)
tion and evaluation is done at the outer wall surface of the Re0.2

13
Heat Mass Transfer

Fig.  8  a Friction factor com- (a) 70.000

parison of DCST and plain tube;
(λ vs. Re). b Friction factor
comparison of DCST and plain 60.000
tube; λP/λT versus Re

50.000

40.000

λ
30.000

20.000
λDarcy-Weisbach Fricon Factor*1000
λ5cm*1000
10.000
λ10cm*1000
λ15cm*1000
0.000
5000 10000 15000 20000 25000
Re

(b) 2.000

1.800

1.600

1.400

1.200
Nu

1.000

0.800

0.600
λpT/λ5cm
0.400
λpT/λ10cm
0.200
λpT/λ15cm
0.000
5000 10000 15000 20000 25000
Re

2.7.2 Heat transfer calculations readings obtained for plain tube tends to bend greater
towards deviations of more than 90 % for which the simul-
Dittus–Boelter Equation [20]: taneous action of natural and forced convection are held
accountable. It is worthy to note that natural convection
NuPT,Theo = 0.023 ∗ Re0.8 ∗ Pr0.4 ; for Re > 104 (14) phenomena is more pronounced and dominating at lower
Sieder-Tate Equation [21]: values of Reynolds number whereas forced convection
ruled the upper limits of Reynolds number.
µ 0.14
 
NuPT,Theo = 0.023 ∗ Re0.8 ∗ Pr0.4 ∗
µs
; for Re > 104 (15) 2.7.3 Thermal performance calculations
 0.14
µ
µs is known as viscosity correction factor and falls At constant pumping power
very close to 1, hence was taken unity for all calculations.    
When the ratio was measured for wide range of Reynolds  ∗ Re3 =  ∗ Re3
PT T (16)
number (especially at lower values), the experimental

13
 Heat Mass Transfer

T
1
3 well within the agreement depicted by the graphical trends
RePT = ReEquivalent = ReT (17)
PT
NuT

NuPT
η=  (18)
0.333
T
PT
3 Results and discussion
3.1 Heat transfer analysis
3.1.1 Plain tube
The first step before starting the experiments that had any
inclusions of varying pitch turbulators was to measure plain
tube readings keeping several parameters in mind to be cal-
culated. Nusselt number is one of such parameters which,
sequentially is thought to be measured under an unvary-
ing or constant condition of heat flux. Then compared the
obtained results for convective heat transfer coefficient and
Nusselt number vis-à-vis the results that were obtained
from the fundamental equations given by Dittus–Boelter, as
mentioned in Eq. (14). The main motive behind conduct-
ing the plain tube experiments was the experimental vali-
dation of plain tube. From Fig. 5, it can be concluded that
the results obtained from plain tube experiments, for heat
transfer i.e., the trend followed by the graph representing
the variation of Nusselt number with Reynolds number lies
formed by Eq. (14).
3.1.2 Dcst of different pitches
When DCST with different pitches (P  = 5, 10 and 15)
were inserted in internal copper tube of double pipe
heat exchanger, it exhibited different trends when the
graph between the obtained experimental values of Nus-
selt number and Reynolds number was plotted, which
is depicted in Fig. 6a, b. While analyzing the graph, it
is clear that the rate of heat transfer is significantly
enhanced when the plain tube and tube with DCST-C
with various pitches are compared for a given fixed value
of Reynolds number.
Hence, obstruction, or resistance to flow, caused by
DCST-C is the phenomenon which is accountable for
such enhancement, which significantly increases with
decreasing pitch. This obstruction intrigues the thermal
boundary layer destruction adjacent to the inner tube wall
leading to swirl flow and local turbulent zones thereby
augmenting the heat transfer and heat transfer ratio with
increase in Reynolds number. This, on the other side,
agitates the entirety of thermal boundary layer thereby
increasing the value of heat transfer coefficient.
While contemplating the quantitative analysis the results
concluded that the heat transfer rate of the tube having
DCST-C at different pitches is found within the range of 1.1–
1.6 times higher vis-à-vis the heat transfer rate for plain tube.

Fig. 9  Thermal performance 1.06

factor versus Reynolds number η, p=5 cm
1.04 η, p=10 cm

η, p=15 cm
1.02

0.98
η

0.96

0.94

0.92

0.9
9000 14000 19000 24000 29000 34000 39000
Re

13
Heat Mass Transfer
3.2 Friction factor analysis
3.2.1 Plain tube
Friction Factor is the first parameter that is measured before
commencing any experiments related to DCST-C, i.e.,
when the apparatus is freshly fabricated, so as to validate
and verify the plain inner copper tube for pressure drop
and friction factor by comparing to the standard data under
optimal experimenting conditions. The obtained results
of friction factor were then compared vis-à-vis the results
obtained from the fundamental equations given by Blasius
and Colburn as mentioned in Eqs. (12) and (13).
From Fig. 7, it can be concluded that the results obtained
from plain tube experiments, for friction factor i.e., the
trend followed by the graph representing the variation of
friction factor with Reynolds number lies well within i.e.,
±10 to ±13 % agreement depicted by the graphical trends
formed by Eqs. (11) and (12). Darcy–Weisbach equation
was used for calculating experimental values of friction
factor.
3.2.2 Dcst of different pitches
Experiments were performed under unvarying or constant
conditions of heat flux for measuring the effect of inserting
DCST-C of different pitches viz. 5, 10 and 15 cm. To obtain
the friction factor and to plot the trend followed, calcula-
tions were made when friction factor varied with the vary-
ing Reynolds number. The results hence obtained were com-
pared with that obtained while using plain inner copper tube.
In Fig. 8a, b, the trend indicates an increment in fric-
tion factor with a decrease in DCST-C pitches. The reason
behind this phenomenon was that the less is the distance
between two consecutive DCST-C the more are the DCST-
C that can be mounted on the cylindrical rod and hence
inserted in inner copper tube, consequently causing more
obstruction to the hot water stream, and hence more is the
turbulence induced resulting in larger pressure drop and
hence increase in friction factor.
3.3 Thermal performance factor
At this stage, experimentation involved DCST with vary-
ing pitches, which includes an augmentation of heat trans-
fer rate, though with a simultaneous increment in friction
factor with decrease in pitch. The criteria of decreas-
ing pitches comes at a price, that is, every extra turbula-
tors inserted cause an extra resistance to flowing water
and hence leading to an increment in friction factor. The
more is the obstruction caused the more will be the effort
required by pump to sustain a constant mass flow rate and
hence more will be the pumping power required which at
a certain level proves to be uneconomical. Consequently,
a mutual agreement or an optimum state has to be con-
cluded between the effectiveness of DCST in heat transfer
augmentation and the increase in friction factor it causes.
This problem is to be judged from performance evaluation
criteria.
As depicted in Fig. 9, when graph is plotted between
thermal performance factor and Reynolds number that at
constant pumping power, with an increase in Reynolds num-
ber there is a decrease in thermal performance factor. Also,
it can be seen that, for same pumping power DCST with
P = 15 cm proved to be most efficient, the reason being the
least friction offered by this pitch of DCST springs.
13
 Heat Mass Transfer

3.4 Comparision of performance parameters

of different mechanical turbulators

S.No. Authors Configuration name Configuration design Reynolds no. Heat transfer Friction factor
range

1 Promvonge et al. [14] Twisted tape 2000–12,000 140 % < Nu < 228 % 200–386 %

2 Kumbhar and Sane [17] Conical wire coil inserts 2000–10,000 5 % < Nu < 12 % 40–66.7 %

3 Eiamsa-ard et al. [18] Nozzle Turbulators 8000–18,000 212 % < Nu < 300 % Pressure drop

increased
250–800 Pa/m

4 Kongkaitpaiboon et al. Perforated conical rings 4000–20,000 200 % < Nu < 350 % Increased by 6

[19] times

5 Present work Divergent convergent 5000–40,000 11.46 % < Nu < 26.76 % 20.79–66.87 %

spring turbulators

13
Heat Mass Transfer

In present work, Nusselt number (Nu) is increased by only
15.3 % at the expense of 66.21 % increase in friction factor
for Reynolds no. range (5000–40,000), whereas maximum
increase in Nusselt number is claimed by Kongkaitpaiboon
et al. [19]. which is 150 % but at the expense of 6 times
increase in friction factor for Reynolds no. range (4000–
20,000) and it is well known that by increasing the Reyn-
olds number friction factor increases and hence, increase
the required pumping power which makes the process
uneconomical.
So, in present work a wide range of Reynolds number
is used and at higher Reynolds number increase in friction
factor is in well acceptable range which is much lower as
compared with the previous studies.
4 Conclusion
The objectives mentioned are successfully performed in the
range of cold water varying from 500 to 1500 LPH and hot
water ranging from 500 to 2000 LPH, thereby obtaining a
wide range of Reynolds number from as low as 9000 to as
high as 40,000. The effects of DCST-C with varying pitch
ratios when inserted in inner plain tube of double pipe heat
exchanger are studied including their role in heat transfer
augmentation. The most significant conclusions that are
drawn after performing this experiment are as:
(a) Keeping the experimentation conditions approximately
identical, Heat transfer augmentation, is best provided
by using DCST-C with P = 5 cm. It depicts an inverse
trend where Nusselt number ratio (thermal efficiency)
decreases with increase in Reynolds number. It can be
comprehended as the relative effect of plain tube and
tubes with DCST-C installed, on heat transfer augmen-
tation. Hence, it can be concluded that DCST-C (best
results given by DCST-C with P  = 5 cm) performs
great at relatively lower values of Reynolds number
and their effect, not sharply but gradually decreases
with increment in Reynolds number.
(b) The Nusselt number is found to be enhanced by 11.46,
17.88 and 26.76 % with DCST-C pitches P  = 15, 10
and 5 cm, vis-à-vis plain tube.
(c) Friction factor and pressure drop characteristics were
also studied and evaluated. It reveals that, with an
increment in DCST-C pitch, friction factor and pres-
sure drop increases. DCST-C offers a maximum of
20.79, 48.59 and 66.87 % friction factor with 15, 10
and 5 cm respectively, vis-à-vis friction factor gener-
ated by plain tube.
(d) Thermal performance factor offered by DCST-C with
varying pitches is also studied and it is found that the
DCST-C with high pitch generates least amount of
friction factor vis-à-vis DCST-C with P = 10 cm and
P  = 15 cm, which leads to a maximum thermal per-
formance factor of 1.0525. Thermal performance fac-
tor for P  = 15 cm was 6 % more than DCST with
P = 10 cm and 8 % more than DCST-C with P = 5 cm
and that too at same pumping power.
The experiment for augmentation of heat transfer is suc-
cessfully performed with DCST-C arrangement in dou-
ble pipe heat exchanger and heat transfer (Nusselt no) is
enhanced by 26.76 %, Friction factor is increased maxi-
mum of 66.87 % for DCST-C pitch 5 cm vis-à-vis plain
tube. However, thermal performance factor gives maximum
value 1.0525 for DCST-C pitch 15 cm.
Compliance with ethical standards 
Conflict of interest  The authors declare no conflict of interest.
Appendix
See Tables 1, 2, 3, 4 and 5.

Table 1  .
For large rotameter
LPH m (kg/s) T (s) Observation I (kg) m1 (kg/s) Observation II (kg) m2 (kg/s) Observation III (kg) m3 (kg/s) Mavg % Error

800 0.22666 180 39.9 0.22166 40.3 0.22388 40.1 0.22277 0.22277 1.71568
900 0.255 180 44.8 0.24888 44.7 0.24833 44.9 0.24888 0.24888 2.39651
1000 0.28333 180 49.6 0.27555 49.9 0.27722 49.8 0.27648 0.27648 2.4183
1100 0.31166 180 54.5 0.30277 54.7 0.30388 54.7 0.30351 0.30351 2.61437
1200 0.34 180 60.1 0.33388 59.8 0.33222 59.7 0.33259 0.33259 2.19864

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 Heat Mass Transfer

Table 2  .
For small rotameter
LPH m T Observation I (kg) m1 (kg/s) Observation II (kg) m2 (kg/s) Observation III (kg) m3 (kg/s) Mavg % Error
(kg/s) (s)

300 0.08333 180 14.9 0.08277 14.6 0.08111 14.75 0.08194 0.08194 1.66273
400 0.11333 180 20.1 0.11166 20.1 0.11166 20.2 0.11222 0.11185 1.30719
500 0.14166 180 25.2 0.14 25.1 0.13944 25 0.13888 0.13944 1.56862
600 0.17 180 30.3 0.16833 30.1 0.16722 30 0.16666 0.1674 1.52505
700 0.19833 180 35.1 0.195 35 0.19444 35.1 0.195 0.19481 1.77404

Table 3  . RTD calibration

T1 T4 T5 T8

Obs. I 34.1 34.1 35 34.1

Obs. II 35.1 33.9 34 33.9
Obs. III 34.1 35.1 34.1 35.1
Obs. IV 34.1 34.9 33.9 33.9
Obs. V 35.1 35.1 35.1 33.9
Obs .VI 34.1 34.1 33.9 35.1
Obs. VII 33.9 34 34.1 34.1
Obs. VIII 34 33.9 34 34
Calibration ±1 ±1 ±1 ±1

Table 4  . Experimental data for repeatability

Heat transfer versus Re for DCST having pitch 15 cm
mcw, mhw T1 T2 T3 T4 Rehw Trial 1 Trial 2 %diff
Nu Exp Nu Exp

0.113 35.9 57 75.8 57.1 9712.452 59.067 63.044 −6.732

0.141 35.8 56.2 75.8 57.9 12043.41 73.314 74.622 −1.783
0.17 35.8 55.8 75.9 58.6 14457.88 88.222 87.217 1.138
0.198 35.9 55.7 75.9 59.6 17115.7 97.27 98.551 −1.317

Table 5  . Experimental data for repeatability

Heat transfer versus Re for DCST having pitch 10 cm
mcw, mhw T1 T2 T3 T4 Rehw Trial 1 Trial 2 %diff
Nu Exp Nu Exp

0.113 36.2 58.1 76.3 57.1 9643.4 62.77 64.32 −2.482

0.141 36.2 57.7 76.2 57.6 12043.41 77.715 78.9 −1.534
0.17 36.3 56.9 76.2 58.6 14457.88 92.489 91.31 1.269
0.198 36.3 56.7 76.1 59.6 17115.7 103.88 107.66 −3.642

13
Heat Mass Transfer

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