Double Pipe heat Exchanger (DPHE)
10000 kg/hr of a hydrocarbon is cooled from 120°C to 80°C using water at 30°C which is heated to
50°C. Hydrocarbon flows in the annulus and water in the tubes. The inner diameter of inner tube is 50
mm with thickness 2 mm and inner diameter of outer tube is 75 mm with thickness 2.2 mm respectively.
The dirt factor values are 0.000051m2K/W for both the sides. Length of exchanger is 12 ft. The
maximum pressure drop permissible on both sides are 20psi. % oversurface and % overdesign should
not exceed 30%.
Caution: For obtaining any other information use Perry Hand Book given to you. Don’t make
unnecessary assumptions without justifying them. Give answers upto three decimals only and don’t
round off values in each step as it leads to accumulation of error. Write down the formulas legibly and
state all the terms involved in it along with its units. The physical properties of hydrocarbon and water
at their mean temperatures are given below.
Properties Water Hydrocarbon
Thermal conductivity 0.673 W/mK 0.3 W/mK
3
Density 996 Kg/m 798 Kg/m3
Viscosity 0.66 cP 0.46 cP
Specific heats 4178 kJ/Kg 2710 kJ/Kg
Viscosity at wall temp. 0.47 cP 0.51 cP
The following assumptions are made – 1. Negligible heat loss to the surroundings
2. Constant properties at mean temperatures
3. Negligible wall tube thermal resistances
4. Fully developed flow conditions for both fluids
5. Conter current flow pattern
6. Hair pins are connected in series
Design suitable Double Pipe Heat Exchanger required for above process in detail as given.
a) Calculate the inside, outside, clean and dirt overall coefficients by considering viscosity
correction factors [20M]
b) Calculate the number of hair pins [5M]
c) Inside and outside pressure drops by neglecting nozzle and other minor losses [15M]
d) Power required for pumping using 70% efficiency of pump [5M]
e) Report % oversurface and % overdesign [5M]
f) Mechanical design stating type of support, gaskets, diameter of nozzle for both the sides and
flange design [20M]
g) Draw a neat sketch of DPHE [30M]
Note: You may use the following equations for calculations if necessary
Equation 1: For transition flow Equation 2: For calculating wall temperature
Where tave for the fluid in the inner pipe, Do and D i are outer and inner diameters of the inner pipe,
Tave for the fluid in the annulus
Generally, the scheme for the answers runs as shown below
a) Performing energy balance and calculating heat duty with unknown flowrate – 1+2M
b) Calculation of Reynolds number for tube side along with linear velocity and equivalent
diameter – 1+1+1M
c) Calculation of inside heat transfer coefficient by mentioning suitable equation – 2+2M
d) Calculation of Reynolds number for annulus side along with linear velocity and equivalent
diameter – 1+1+1M
e) Calculation of outside heat transfer coefficient by mentioning suitable equation – 2+2M
f) Calculation of overall heat transfer coefficient with formula – 2+1M
g) Calculate the number of pins – 5M
h) Calculation of tube side friction factor, pressure drop, pressure drop due to return bends and
total pressure drop – 2+3+2+1M
i) Calculation of annulus side friction factor, pressure drop, pressure drop due to return bends and
total pressure drop – 1+2+2+2M
j) Power required for pumping on both sides – 5M
k) % Over design and % Over surface – 3+2M
l) State type of support with reason – 5M
m) Gaskets – 5M
n) Finding diameter of nozzle for both the sides – 5+5M
o) Drawing of DPHE on sheet or computer – 20M
p) Dimensioning of DPHE with scale – 5M
q) Labelling the parts of DPHE and neatness – 5M
