MODELLING OF EFFECTIVENESS OF DOUBLE

PIPE HEAT EXCHANGER USING DESIGN OF

EXPERIMENTS

G78 Project

Submitted by
DINESH, T
(Reg. No: 12G22)
SUNDAR, G
(Reg. No:12G101)

In partial fulfillment for the requirement of B.E. degree in Mechanical

Engineering of Anna University

Guided by

Dr. A. VALAN ARASU Ph.D. PDF.

Associate. Professor

Department of Mechanical Engineering

THIAGARAJAR COLLEGE OF ENGINEERING

(A Govt. Aided ISO 9001:2008 certified Autonomous Institution Affiliated to Anna University)

MADURAI – 625 015

November 2015

1
 THIAGARAJAR COLLEGE OF ENGINEERING
(A Govt. Aided ISO 9001:2008 certified Autonomous Institution Affiliated to Anna University)

MADURAI – 625 015.

CERTIFICATE

Certified that this is a bonafide record of the G78 Project & Viva Voce done
by Mr. Dinesh T (12G22) and Mr. Sundar G (12G101) of Seventh Semester
B.E. (Mechanical Engineering) during the year 2015 - 2016.

Signature of the Guide Signature of H.D.M.E

Station: Madurai
Date:

Submitted for Viva-Voce examination held at Thiagarajar College of Engineering,

Madurai – 625 015, on __________________.

INTERNAL EXAMINER EXTERNAL EXAMINER H.D.M.E.

ii
 CERTIFICATE

This is to certify that the G78 Project Report entitled “Modelling of effectiveness of

double pipe heat exchanger using Design Of Experiments ”, being submitted by Mr.

Dinesh T (12G22) and Mr. Sundar G (12G101) in partial fulfillment for the

requirement of Bachelor of Engineering Degree in Mechanical Engineering, is a

record of bonafide work. The results embodied in this report have not been submitted to

any other university or institute for the award of any degree or diploma.

DINESH T DR. A VALAN ARASU

(STUDENT) (GUIDE)

SUNDAR G
(STUDENT)

Station: Madurai
Date:

iii
 ACKNOWLEDGEMENT

We are pleased to convey our sincere thanks to our principal Dr. V.Abhaikumar
for providing us the facilities to do this project.

We are grateful to Dr. C. Muruganantham, Professor and Head of Mechanical

Engineering Department, for his energetic encouragement.

We express our deep sense of gratitude and indebtedness to Dr. A. Valan Arasu,
Associate Professor in Mechanical Engineering Department, for his inspiring
guidance and encouragement, which has enabled us to do this project.

Also we would like to thank all our teachers, friends and well-wishers who have
helped us for this project.

DINESH T
SUNDAR G

iv
 LIST OF CONTENTS
Chapter TITLE Page No.
No
Title Page i
Bonafide Certificate ii
Certificate iii
Certificate (Applicable Only For Industrial Project)
Acknowledgement iv
List Of Contents v
List Of Figures vi
List Of Tables vii
Abstract viii
1 Introduction
1.1 Introduction 1
1.2 Overview of the project 2
2 Literature review 3
3 Basic concepts and theory
3.1 The Taguchi method an introduction 4
3.2 Signal to Noise ratio 4
3.3 Interactions 5
3.4 Degrees of freedom 6
3.5 Orthogonal array 6
3.6 Double pipe heat exchanger 8
3.7 Algorithm 10
3.7.1 Problem formulation 10
3.7.2 Selection of factors 10
3.7.3 Determination of levels 10

v
3.7.4 Interactions identification 11
3.7.5 Degrees of freedom 11
3.7.6 Selection of orthogonal array 11
3.8 Statistical procedure 12
4 Experiment and results
4.1 Statistical analysis 13
4.2 Factor ranking 14
4.3 Analysis of variance 16
4.4 Regression equation 17
4.5 Determination of optimal factor levels 18
5 Conclusion 20
6 Reference 21
7 Annexure 22

LIST OF FIGURES
Figure Description Page No.
No.
4.1 Main effects plot for S/N ratio 18
4.2 Main effects plot for mean 19

vi
 LIST OF TABLES
Table Description Page No.
No.
3.1 Orthogonal array selector 7
3.2 L9 orthogonal array 8
3.3 Values for the parameters 10
3.4 Level values in L9 orthogonal array 12
4.1 Experimental results and S/N ratios 13
4.2 Orthogonal array and their S/N ratios 14
4.3 MH and their S/N ratios 15
4.4 Factor ranking 15
4.5 Analysis of variance for S/N ratios 16
4.6 Analysis of variance for effectiveness 17
4.7 Experimental and predicted effectiveness 17
4.8 Optimal factor level 18
4.9 Order of Factor influencing the response variable 19

vii
 ABSTRACT

Design of Experiments tool is applied on a double pipe heat exchanger. Taguchi design
methodology is applied with inlet temperature of hot fluid, mass flow rate of hot and cold
fluids as factors. The effectiveness of the exchanger is taken as the responsible variable.
Three levels are set for the above factors and the experiments are performed based on the
appropriate orthogonal array. From the obtained results Signal to Noise (S/N) ratio is
calculated. Sorting of Signal to noise ratio gives the most influencing factor on the
response variable and ANOVA table for the response variable and Signal to Noise ratio
are drawn. Regression analysis gives an equation for the effectiveness of the heat
exchanger. Using MINITAB16.0 the main effects plot for means and S/N ratio is
obtained from which the optimal levels of factors are inferred. The values of selected
levels of factors are substituted in the regression equation to find the maximum
effectiveness value.

Keywords: Design of Experiments, Taguchi method, effectiveness, S/N ratio, ANOVA,

regression.

viii
 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

The term experiment is defined as the systematic procedure carried out under controlled
conditions in order to discover an unknown effect, to test or establish a hypothesis, or to
illustrate a known effect. When analyzing a process, experiments are often used to
evaluate which process inputs have a significant impact on the process output, and what
the target level of those inputs should be to achieve a desired result (output).

Experiments can be designed in many different ways to collect this information. A non-
optimal design requires a greater number of experimental runs to estimate the parameters.
Hence, Design of Experiments (DOE) also referred as Designed experiments is a
systematic method to determine the relationship between factors affecting a process and
the output of that process is used. In other words, it is used to find cause-and-effect
relationships. This information is needed to manage process inputs in order to optimize
the output.

Designed Experiments is used at the point of greatest leverage to reduce design costs by
speeding up the design process, reducing late engineering design changes, and reducing
product material and labor complexity.

Designed Experiments are also powerful tools to achieve manufacturing cost savings by
minimizing process variation and reducing rework, scrap, and the need for inspection.

Heat exchangers are devices that facilitate the exchange of heat between two fluids that
are at different temperatures while keeping them from mixing with each other. Heat

1
exchangers are commonly used in a wide variety of applications, from heating and air-
conditioning systems in a household, to chemical processing and power production in
large plants. Heat exchanger operations are very costly and operating them at ideal
conditions will give effective results. Hence it is very important to optimize these
operations to minimize the overall operating costs and to increase its effectiveness

1.2 OVERVIEW OF THE PROJECT

The main objective of the present work is to analyze the influence of considered factors
and rank them on the basis of degree of influence on the preferred response variable and
to solve the regression equation based on the considered factors. This study also aims to
find out the optimum parameter value setting for maximum effectiveness of the
considered experimental system. Essentially this study is aimed to optimize the number
of experiments performed in the heat exchanger. The results obtained from optimum
number of experiments are fed into MINITAB 16.0 to obtain ANOVA tables and
regression equation.

Chapter 1 provides the introduction and overview to the current project. The
previous literatures related to this project is identified and briefed in Chapter 2.The theory
involved in the designed experiments and the procedure are explained in detail in chapter
3. Moreover the optimum number of experiments to be conducted is also discussed in
detail. Chapter 4 comprises of experimentation and results. The conclusion for the
project has been summarized in Chapter 5.

2
 CHAPTER 2

LITERATURE REVIEW

RAMKUMAR et al [1] studied the cooling tower performance using Taguchi

method. In this they form the regression equation for effectiveness and find the error
between theoretical and obtained regression equation effectiveness.

Elizabeth A. Cudney et al [2] applied the Ad joint Matrix Approach to

Mahalanobis Taguchi System for vehicle braking to identify a reduced set of useful
variables in multidimensional systems.

Shubhra Banerji [3] proposed Orthogonal Array Approach for reducing the
number of test cases that needs to be tested for any given software and hence improve the
efficiency of testing.

Krishankant et al [4] reported an optimization of turning process by the effects of

machining parameters applying Taguchi methods to improve the quality of manufactured
goods, and engineering development of designs for studying variation.

Raghu N. Kacker et al [5] described the structure and constructions of Taguchi's

orthogonal arrays and illustrated their fractional factorial nature, and points out that
Taguchi's catalog can be expanded to include orthogonal arrays developed.

3
 CHAPTER 3

BASIC CONCEPTS AND THEORY

3.1 THE TAGUCHI METHOD AN INTRODUCTION

This is an experimental design principle devised by Genichi Taguchi, a Japanese engineer

who supports the objective of designing quality into every product and corresponding
process. In Taguchi’s method, quality is measured by the deviation of a characteristic
from its target value. A loss function is developed for this deviation. Uncontrollable
factors, such as noise, can cause such deviation and thereby to loss.

Since the elimination of noise factors is impractical and often impossible, the Taguchi
method seeks to minimize the effects of noise and to determine the optimal level of the
important controllable factors based on the concept of robustness. The objective is to
create a process design that is insensitive to all possible combinations of the
uncontrollable noise factors and is at the same time effective and cost-efficient as result
of setting the key controllable factors at certain levels.

3.2 SIGNAL TO NOISE RATIO

Signal-to-noise ratio (abbreviated SNR) is a measure used in science and engineering that
compares the level of a desired signal to the level of background noise. It is defined as
the ratio of signal power to the noise power, often expressed in decibels. It was developed
as a proactive equivalent to the creative loss function. A ratio higher than 1:1 (greater
than 0 dB) indicates more signal than noise. Signal-to-noise ratio is defined as the ratio of
the power of a signal (meaningful information) and the power of background noise.

4
Where P is average power, both signal and noise power must be measured at the same or
equivalent points in a system, and within the same system bandwidth.

3.3 INTERACTIONS

An interaction may arise when considering the relationship among three or more
variables, and describes a situation in which the simultaneous influence of two variables
on a third. Most commonly, interactions are considered in the context of regression
analyses.

The presence of interactions can have important implications for the interpretation of
statistical models. If two variables of interest interact, the relationship between each of
the interacting variables and a third "dependent variable" depends on the value of the
other interacting variable. In practice, this makes it more difficult to predict the
consequences of changing the value of a variable, particularly if the variables interact
with are hard to measure or difficult to control.

An "interaction variable" is a variable constructed from an original set of variables to try

to represent either all of the interaction present or some part of it. In exploratory
statistical analyses it is common to use products of original variables as the basis of
testing whether interaction is present with the possibility of substituting other more
realistic interaction variables at a later stage. When there are more than two explanatory
variables, several interaction variables are constructed, with pairwise-products
representing pairwise-interactions and higher order products representing higher order
interactions.

But Interactions use degrees of freedom; therefore, more treatment conditions are needed
or fewer factors must be used. As long as interactions are relatively mild, main effect

5
analysis will give the optimal results and good dispersed among all the factors. Hence it
is imperative that control factors that will have least or minimal interactions among
themselves must be selected.

3.4 DEGREES OF FREEDOM

The number of degrees of freedom is important because it determines the optimum
number of experiments to be performed.

No of experiments = Nf (Nl -1) + (Nl -1)2 Ni + 1.

Nf – number of factors.
Nl – number of levels.
Ni – number of interactions.

3.5 ORTHOGONAL ARRAY

Orthogonal arrays are a simplified form of putting together an experiment. Taguchi's
catalog of orthogonal arrays is used to plan industrial experiments. But Taguchi provides
either no information or insufficient information on the methods that were used to
construct these arrays. Moreover, Taguchi displays orthogonal arrays in forms that are
different from the way these arrays are usually displayed in the statistical literature.

To select the appropriate orthogonal array, the following procedure is followed

1. Define the number of factors and their levels.
2. Determine the degrees of freedom.
3. Select an Orthogonal array.
4. Consider any interactions.
Knowing the number of parameters and the number of levels, the proper orthogonal array
can be selected. Using the array selector table shown below, the name of the appropriate

6
array can be found by looking at the column and row corresponding to the number of
parameters and number of levels. These arrays were created using an algorithm Taguchi
developed, and allows for each variable and setting to be tested equally.

Table 3.1 Orthogonal array selector.

Number of levels
2 3 4 5
Number of 2 L4 L9 L’16 L25
parameters 3 L4 L9 L’16 L25
(P) 4 L8 L9 L’16 L25
5 L8 L18 L’16 L25
6 L8 L18 L’32 L25
7 L8 L18 L’32 L50
8 L12 L18 L’32 L50
9 L12 L27 L’32 L50
10 L12 L27 L’32 L50
11 L12 L27 L50
12 L16 L27 L50
13 L16 L27
14 L16 L36
15 L16 L36
16 L32 L36
17 L32 L36
18 L32 L36
19 L32 L36
20 L32 L36
21 L32 L36
22 L32 L36
23 L32 L36
24 L32
25 L32
26 L32
27 L32
28 L32
29 L32
30 L32
31 L32

7
Table 3.2 L9 ORTHOGONAL ARRAY

Experiment No. Column 1 Column 2 Column 3

1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2

3.6 DOUBLE PIPE HEAT EXCHANGER

Heat exchangers are devices that exchange the heat between two fluids of different
temperatures that are separated by a solid wall. The temperature gradient or the
differences in temperature facilitate this transfer of heat. Transfer of heat happens by
three principle means: radiation, conduction and convection. In the use of heat
exchangers radiation does take place. However, in comparison to conduction and
convection, radiation does not play a major role. Conduction occurs as the heat from the
higher temperature fluid passes through the solid wall. To maximize the heat transfer, the
wall should be thin and made of a very conductive material. The biggest contribution to
heat transfer in a heat exchanger is made through convection. In a heat exchanger forced
convection allows for the transfer of heat of one moving stream to another moving
stream. With convection as heat is transferred through the pipe wall it is mixed into the
stream and the flow of the stream removes the transferred heat. This maintains a
temperature gradient between the two fluids.

The double-pipe heat exchanger is one of the simplest types of heat exchangers. It is
called a double-pipe exchanger because one fluid flows inside a pipe and the other fluid

8
flows between that pipe and another pipe that surrounds the first. This is a concentric tube
construction. Flow in a double-pipe heat exchanger can be co-current or counter-current.
There are two flow configurations: co-current is when the flow of the two streams is in
the same direction, counter current is when the flow of the streams is in opposite
directions (The latter is selected to perform this experiment). As conditions in the pipes
change: inlet temperatures, flow rates, fluid properties, fluid composition, etc., the
amount of heat transferred also changes. This transient behavior leads to change in
process temperatures, which will lead to a point where the temperature distribution
becomes steady. When heat is beginning to be transferred, this changes the temperature
of the fluids. Until these temperatures reach a steady state their behavior is dependent on
time. In this double-pipe heat exchanger a hot process fluid flowing through the inner
pipe transfers its heat to cooling fluid flowing in the outer pipe. The system is in steady
state until conditions change, such as flow rate or inlet temperature. These changes in
conditions cause the temperature distribution to change with time until a new steady state
is reached. The new steady state will be observed once the inlet and outlet temperatures
for the process and coolant fluid become stable. In reality, the temperatures will never be
completely stable, but with large enough changes in inlet temperatures or flow rates a
relative steady state can be experimentally observed. Thus the effectiveness value can be
𝑚ℎ 𝑐𝑝,ℎ (𝑇ℎ,𝑖 −𝑇ℎ,𝑜 )
obtained by for Cmin = mhcph.
𝐶𝑚𝑖𝑛 (𝑇ℎ,𝑖 −𝑇𝑐,𝑖 )

Where, mh – mass flow rate of hot fluid.

Cp,h - specific heat capacity of hot fluid.

Th,i – inlet temperature of hot fluid.

Th,o – outlet temperature of hot fluid.
Tc,i – inlet temperature of cold fluid.

9
3.7 ALGORITHM
The following steps are the procedure for following Taguchi method. They are as
follows,
1. Problem formulation.
2. Select process parameters or factors.
3. Ascertain levels.
4. Interactions identification.
5. Selection of orthogonal array.

3.7.1 Problem formulation:-

Problem formulation is as discussed in the objective.
3.7.2 Selection of factors:-
The factors identified are
1. Inlet temperature of hot fluid (TH)
2. Mass flow rate of hot fluid (MH).
3. Mass flow rate of cold fluid (MC).
The selected factors should be independent factors. These are basic parameters
which are not influenced by other process parameters.

3.7.3 Determination of levels:-

Three levels are chosen for each factor which is minimum medium and maximum. The
levels are decided by the experimenter.
Table no 3.3 values for the parameters.
Parameter values.
Level 1 2 3
Inlet Temperature of 50 60 70
hot fluid( oC)
Hot fluid mass flow 32.4 63.0 93.6
rate (kg/hr.)
Cold fluid mass 114.6 144.0 174.2
flow rate (kg/hr.)

10
3.7.4 Interactions identification:-
For a given number of factors (Nf), the number of interactions increases exponentially.
But possible theoretical interactions are between two factors only, and they are given
𝑁𝑓! 𝑁𝑓(𝑁𝑓−1)
by = . In the considered study the interaction effects between the
2!(𝑁𝑓−2)! 2

selected factors are not feasible. Hence these effects are not considered for further
calculations.

3.7.5 Degrees of freedom:-

The number of degrees of freedom is important because it determines the minimum
number of treatment conditions. It is given by

No of experiments = Nf (Nl -1) + (Nl -1)2 Ni + 1.

= (𝟑 − 𝟏) ∗ (𝟑 − 𝟏) + 𝟏 = 𝟕
For our case the D.O.F is 7. This degree of freedom denotes the number of experiments
to be performed.

3.7.6 Selection of orthogonal array:-

Taguchi framed the algorithm and he standardized the array for the required levels and
considered factors. Thus for the required criteria the array required is L9 array which is
selected from the array selector using the degree of freedom value. The required
orthogonal array is given below.

11
Table 3.4 Level values in L9 orthogonal array

Ex.NO MH MC TH
1. 32.4 114.6 50
2. 32.4 144 60
3. 32.4 174.2 70
4. 63 114.6 60
5. 63 144 70
6. 63 174.2 50
7. 93.6 114.6 70
8. 93.6 144 50
9. 93.6 174.2 60

3.8 STATISTICAL PROCEDURE

After following the above procedures, the numbers of experiments given by the
orthogonal array are performed and data are obtained. Then they are subjected to
ANOVA analysis and further formulated into a statistical equation whose input values are
the three factors and give the effectiveness value.

12
 CHAPTER 4

EXPERIMENT AND RESULTS

4.1 STATISTICAL ANALYSIS

Statistical analysis like S/N ratio, ANOVA, Regression analysis are carried out for a
confident level of 95%, i.e., for significance level of 0.05. The table below (4.1) is the
results obtained from experiment.

TABLE 4.1 Experimental Results and S/N Ratios

EXPERIMENTAL
S.NO MH MC TH EFFECTIVENESS(e) S/N RATIO
1. 32.4 114.6 50 37.9 31.57
2. 32.4 144 60 39.2 31.87
3. 32.4 174.2 70 40.2 32.08
4. 63 114.6 60 38.3 31.67
5. 63 144 70 39.2 31.88
6. 63 174.2 50 38.1 31.61
7. 93.6 114.6 70 40.1 32.07
8. 93.6 144 50 37.5 31.48
9. 93.6 174.2 60 39.1 31.85

Signal to noise ratio (S/N) in Taguchi method is used to measure the present
variation. The S/N ratio can be defined based on the objective function. There are three
kinds of objective function. Nominal is Better (NB), Smaller is Better (SB) and Larger is
Better (LB). In this study the objective is to get maximum effectiveness, so the objective
function chosen is Larger is Better (LB). S/N ratio of Larger is Better (LB) Equation is as
follows (4.1) [ref. 6].

𝑺 𝟏 𝟏
= −𝟏𝟎𝒍𝒐𝒈 ( ∑𝒏𝒊=𝟏 𝟐) (4.1)
𝑵 𝒏 𝒚𝒊

13
 Where n is the number of measurements and yi the parameters being measured
through the experiments i.e. mean response variable. The experimental results and
corresponding S/N ratios are given in table (4.1).

4.2 FACTOR RANKING

The factors or parameters taken are ranked based on the obtained S/N ratio value.
The table is formulated from this. From the table the parameters are ranked and the most
influencing parameter is identified. The most influencing parameter is hot fluid
temperature. It is found by the following steps:

TABLE 4.2 Orthogonal Array and their S/N ratios

Experiment S/N
MH MC TH
No. ratio
1 1 1 1 31.57
2 1 2 2 31.87
3 1 3 3 32.08
4 2 1 2 31.67
5 2 2 3 31.88
6 2 3 1 31.61
7 3 1 3 32.07
8 3 2 1 31.48
9 3 3 2 31.85

Step 1: for first parameter i.e. mass flow rate of hot fluid MH
From the above table (4.2) select the S/N ratios for level 1,level 2 and level 3 separately
from the MH .

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TABLE 4.3 MH and their S/N ratios

Experiment No. MH S/N ratio

1 1 31.57
2 1 31.87
3 1 32.08
4 2 31.67
5 2 31.88
6 2 31.61
7 3 32.07
8 3 31.48
9 3 31.85

Step 2: Averages for S/N ratios for separate levels.

For level 1 of MH the average is 31.84 kg/hr.
For level 2 of MH the average is 31.72 kg/hr.
For level 3 of MH the average is 31.80 kg/hr.

Step 3: Difference for S/N ratios

Subtract the level having lowest number to level having highest number.
Difference=0.12.
Similarly the steps above are followed for mass flow rate of cold fluid (MC) and hot fluid
temperature (TH) and the results are tabulated in table (4.4) shown below,

TABLE 4.4 Factor Ranking

S/N ratio MH MC TH
S/N p n,1 31.84 31.77 31.55
S/Np n,2 31.72 31.74 31.69
S/N p n,3 31.80 31.84 32.01
Difference 0.12 0.09 0.45

From the above table (4.4) on comparing results of all the three levels, the influencing
factor is temperature of hot fluid. From this, it is inferred that if there is a variation in

15
temperature of hot fluid then there is a variation in the response variable i.e. The
Effectiveness of Double Pipe Heat Exchanger.

4.3 ANALYSIS OF VARIANCE (ANOVA)

ANOVA is a method widely used for determining significant parameters on response

and measuring their effects. In the Heat Exchanger performance the major factor of the
non-reproducibility is to control the test facility and operating condition. In order to
check that parameter the test procedure is standardized and the results are analyzed by the
two way ANOVA. The ANOVA results for S/N ratio and the mean are illustrated in table
(4.5 & 4.6). In ANOVA, the ratio between the variance of the process parameter and the
error variance is called as F-test. It determines whether the parameter has significant
effect on the quality characteristics. This process is carried out by comparing the F-test
value of the parameter with standard F value for 95% confidence level. If the obtained
value is greater than the standard value (F test value) then the factor is significant. The
value of standard F-value is 19(obtained from the table given in ANNEXURE 1), but the
value of F value calculated for hot fluid temperature is 19.22(for S/N ratio) and 19.39(for
mean effectiveness), this confirms that hot fluid temperature is significant. The ANOVA
is calculated using Minitab 16.0.The results of ANOVA are tabulated in table 4.5 and
table 4.6.
TABLE 4.5 Analysis Of Variance for S/N ratios

Source DF Seq. SS Adj. SS Adj. MS F P

MH 2 0.023586 0.023586 0.011793 1.25 0.445
MC 2 0.016632 0.016632 0.008316 0.88 0.532
TH 2 0.363281 0.363281 0.181640 19.22 0.049

Error 2 0.018905 0.018905 0.009452

Total 8 0.422404

16
TABLE 4.6 Analysis Of Variance for Effectiveness

Source DF Seq SS Adj SS Adj MS F P

MH 2 0.4877 0.4877 0.2438 1.30 0.435
MC 2 0.3336 0.3336 0.1668 0.89 0.529
TH 2 7.2736 7.2736 3.6368 19.39 0.0490
Error 2 0.3751 0.3751 0.1875
Total 8 7.4699

Where MH is mass flow rate of Hot Fluid (kg/hr.),

MC is mass flow rate of Cold Fluid (kg/hr.),
TH is temperature of Hot Fluid (oc.).

4.4 REGRESSION EQUATION

By means of Regression and correlation analysis the effect of process parameter on the
response variable of Heat Exchanger was obtained as equation (4.2).This analysis can be
done with the help of Minitab 16.0
Em=32.095-0.0031 MH+0.006 MC+0.102 TH (4.2)

Where E, MH, MC, TH are effectiveness, mass flow of hot fluid, mass flow of cold fluid
and temperature of hot fluid respectively. Effectiveness is dependent variable where as
other three are independent variable.

TABLE 4.7 Experimental and predicted Effectiveness.

S.NO EFFECTIVENESS FROM EFFECTIVENESS FROM

EXPERIMENT(Ee) MODEL (Em)
1. 37.9 37.7
2. 39.2 38.9
3. 40.2 40.1
4. 38.3 38.7
5. 39.2 39.8
6. 38.1 38.02
7. 40.1 39.6
8. 37.5 37.7
9. 39.1 38.9

17
 It is clear that statistical model can predict the heat exchanger effectiveness with
sufficient accuracy depending on the obtained correlation coefficients (R2= 86.76%).This
accuracy is obtained from the summary of Regression analysis in Minitab 16.The
predicted Effectiveness values are tabulated in table (4.7).

4.5 DETERMINATION OF OPTIMAL FACTOR LEVELS

The optimal factor levels can be determined from the Main effect plots of S/N ratios
and means. The plots are given in Fig 4.1 and Fig 4.2 respectively. From the Fig 4.1 and
Fig 4.2 the optimum levels are mass flow rate of hot fluid is 32.4 kg/hr., Mass flow rate
of cold fluid is 174.2 kg/hr., and hot fluid temperature is 70oC. These optimum setting of
control factors maximize the Heat Exchanger Effectiveness. It is shown in table (4.8).
TABLE 4.8 Optimal Factor Level

S.NO MH MC TH E
1 32.4 174.2 70 40.14458

FIG 4.1 Main Effects Plot for S/N ratio

Main Effects Plot for s/n ratio

Data Means
MH MC
32.0
31.9
31.8
31.7
31.6
Mean

32.4 63.0 93.6 114.6 144.0 174.2

TH
32.0
31.9
31.8
31.7
31.6
18
50 60 70
FIG 4.2 Main Effects Plot for Means

Main Effects Plot for MEANS

Data Means

MH MC
40.0
39.5

39.0
38.5
38.0
Mean

32.4 63.0 93.6 114.6 144.0 174.2

TH
40.0
39.5
39.0

38.5
38.0

50 60 70

TABLE 4.9 Order of Factor influencing the response variable,

S.NO MH MC TH E
1 32.4 174.2 70 40.14458
2 93.6 114.6 60 38.61979
3 63 144.6 50 37.84998

The above table 4.9 shows the factors levels and their order. Serial number 1 represents
the most influencing variables and their corresponding levels i.e. it is optimal factor
levels and their corresponding effectiveness are tabulated in table 4.9.

19
 CHAPTER 5

CONCLUSION
5.1CONCLUSION

From the analysis on the results of heat exchanger effectiveness, the following
conclusions were drawn
1. Based on ANNOVA results, all control factors have significant effect on the quality
characteristics statistically.
2. Inlet temperature of hot fluid is the most influencing factor followed by hot fluid flow rate
and then cold fluid flow rate.
3. The optimum experimental condition which gives maximum effectiveness is at hot fluid
temperature at 70 oC, hot fluid flow rate at 32.4kg/hr. and cold fluid flow rate at 174.2kg/hr.

Using Taguchi methods, optimum operating parameters were identified in terms of

high medium or low level. So operating parameter obtained using Taguchi is to be fine-
tuned to improve the performance of heat exchanger.

20
 CHAPTER 6

REFERENCE
1. Ramakrishnan Ramkumar and Arumugam Ragupathy, “Optimization of cooling tower
performance analysis using taguchi method”, thermal science: Year 2013, Vol. 17, No. 2,
pp. 457-470.

2. Elizabeth A. Cudney, Kioumars Paryani, Kenneth M. Ragsdell, “ Identifying Useful

Variables for Vehicle Braking Using the Adjoint Matrix Approach to the Mahalanobis-
Taguchi System”, Journal of Industrial and Systems Engineering,Vol. 1, No. 4, pp 281-
292 Winter 2008

3. Shubhra Banerji, “Orthogonal Array Approach for Test Case Optimization”,

International Journal of Advanced Research in Computer and Communication
Engineering Vol. 1, Issue 9, November 2012.

4. Krishankant, Jatin Taneja, Mohit Bector, Rajesh Kumar, “Application of Taguchi

Method for Optimizing Turning Process by the effects of Machining Parameters”,
International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 –
8958, Volume-2, Issue-1, October 2012

5. Raghu N. Kacker, Eric S. Laguerre, and James J. Filliben, “Taguchi Vs Orthogonal

Arrays Are Classical Designs of Experiments”, Volume 96, Number 5, September-
October 1991,Journal of Research of the National Institute of Standards and Technology.

6. Total Quality Management revised 3rd edition by Dale H. Bester field et al.,
PEARSON, Seventh Impression,2014.

7. Heat and Mass Transfer a practical approach 3rd edition by Yunus A. Cengel, The Mc-
Graw –Hill companies, special Indian Edition 2007.

21
 ANNEXURE
F-table for = 0.05 (95% Confidence Level)

Numerator degrees of freedom

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

161. 199. 215. 224. 230. 234. 236. 238. 240. 241. 243. 245. 248. 249. 250. 251. 252. 253. 254.
1
4 5 7 6 2 0 8 9 5 9 9 9 0 1 1 1 2 3 3

D 2
18.5
1
19.0
0
19.1
6
19.2
5
19.3
0
19.3
3
19.3
5
19.3
7
19.3
8
19.4
0
19.4
1
19.4
3
19.4
5
19.4
5
19.4
6
19.4
7
19.4
8
19.4
9
19.5
0
e 3
10.1
9.55 9.28 9.12 9.01 8.94 8.89 8.85 8.81 8.79 8.74 8.70 8.66 8.64 8.62 8.59 8.57 8.55 8.53
3
n 4 7.71 6.94 6.59 6.39 6.26 6.16 6.09 6.04 6.00 5.96 5.91 5.86 5.80 5.77 5.75 5.72 5.69 5.66 5.63
o 5 6.61 5.79 5.41 5.19 5.05 4.95 4.88 4.82 4.77 4.74 4.68 4.62 4.56 4.53 4.50 4.46 4.43 4.40 4.36

m 6 6.99 5.14 4.76 4.53 4.39 4.28 4.21 4.15 4.10 4.06 4.00 3.94 3.87 3.84 3.81 3.77 3.74 3.70 3.67

7 5.59 4.74 4.35 4.12 3.97 3.87 3.79 3.73 3.68 3.64 3.57 3.51 3.44 3.41 3.38 3.34 3.30 3.27 3.23
i 8 5.32 4.46 4.07 3.84 3.69 3.58 3.50 3.44 3.39 3.35 3.28 3.22 3.15 3.12 3.08 3.04 3.01 2.97 2.93
n 9 5.12 4.26 3.86 3.63 3.48 3.37 3.29 3.23 3.18 3.14 3.07 3.01 2.94 2.90 2.86 2.83 2.79 2.75 2.71

a 1
0
4.96 4.10 3.71 3.48 3.33 3.22 3.14 3.07 3.02 2.98 2.91 2.85 2.77 2.74 2.70 2.66 2.62 2.58 2.54

t 1
4.84 3.98 3.59 3.36 3.20 3.09 3.01 2.95 2.90 2.85 2.79 2.72 2.65 2.61 2.57 2.53 2.49 2.45 2.40
1
o 1
4.75 3.89 3.49 3.26 3.11 3.00 2.91 2.85 2.80 2.75 2.69 2.62 2.54 2.51 2.47 2.43 2.38 2.34 2.30
r 2

1
4.67 3.81 3.41 3.18 3.03 2.92 2.83 2.77 2.71 2.67 2.60 2.53 2.46 2.42 2.38 2.34 2.30 2.25 2.21
3

D 1
4
4.60 3.74 3.34 3.11 2.96 2.85 2.76 2.70 2.65 2.60 2.53 2.46 2.39 2.35 2.31 2.27 2.22 2.18 2.13

e 1
5
4.54 3.68 3.29 3.06 2.90 2.79 2.71 2.64 2.59 2.54 2.48 2.40 2.33 2.29 2.25 2.20 2.16 2.11 2.07

g 1
4.49 3.63 3.24 3.01 2.85 2.74 2.66 2.59 2.54 2.49 2.42 2.35 2.28 2.24 2.19 2.15 2.11 2.06 2.01
6
r 1
4.45 3.59 3.20 2.96 2.81 2.70 2.61 2.55 2.49 2.45 2.38 2.31 2.23 2.19 2.15 2.10 2.06 2.01 1.96
7
e 1
4.41 3.55 3.16 2.93 2.77 2.66 2.58 2.51 2.46 2.41 2.34 2.27 2.19 2.15 2.11 2.06 2.02 1.97 1.92
e 8

1
s 9
4.38 3.52 3.13 2.90 2.74 2.63 2.54 2.48 2.42 2.38 2.31 2.23 2.16 2.11 2.07 2.03 1.98 1.93 1.88

2
4.35 3.49 3.10 2.87 2.71 2.60 2.51 2.45 2.39 2.35 2.28 2.20 2.12 2.08 2.04 1.99 1.95 1.90 1.84
0

O 2
1
4.32 3.47 3.07 2.84 2.68 2.57 2.49 2.42 2.37 2.32 2.25 2.18 2.10 2.05 2.01 1.96 1.92 1.87 1.81

f 2 4.30 3.44 3.05 2.82 2.66 2.55 2.46 2.40 2.34 2.30 2.23 2.15 2.07 2.03 1.98 1.94 1.89 1.84 1.78

22
 2

2
4.28 3.42 3.03 2.80 2.64 2.53 2.44 2.37 2.32 2.27 2.20 2.13 2.05 2.01 1.96 1.91 1.86 1.81 1.76
F 3

2
r 4
4.26 3.40 3.01 2.78 2.62 2.51 2.42 2.36 2.30 2.25 2.18 2.11 2.03 1.98 1.94 1.89 1.84 1.79 1.73

e 2
5
4.24 3.39 2.99 2.76 2.60 2.49 2.40 2.34 2.28 2.24 2.16 2.09 2.01 1.96 1.92 1.87 1.82 1.77 1.71

e 2
6
4.23 3.37 2.98 2.74 2.59 2.47 2.39 2.32 2.27 2.22 2.15 2.07 1.99 1.95 1.90 1.85 1.80 1.75 1.69

d 2
4.21 3.35 2.96 2.73 2.57 2.46 2.37 2.31 2.25 2.20 2.13 2.06 1.97 1.93 1.88 1.84 1.79 1.73 1.67
7
o 2
4.20 3.34 2.95 2.71 2.56 2.45 2.36 2.29 2.24 2.19 2.12 2.04 1.96 1.91 1.87 1.82 1.77 1.71 1.65
8
m 2
4.18 3.33 2.93 2.70 2.55 2.43 2.35 2.28 2.22 2.18 2.10 2.03 1.94 1.90 1.85 1.81 1.75 1.70 1.64
9

3
4.17 3.32 2.92 2.69 2.53 2.42 2.33 2.27 2.21 2.16 2.09 2.01 1.93 1.89 1.84 1.79 1.74 1.68 1.62
0

4
4.08 3.23 2.84 2.61 2.45 2.34 2.25 2.18 2.12 2.08 2.00 1.92 1.84 1.79 1.74 1.69 1.64 1.58 1.51
0

6
4.00 3.15 2.76 2.53 2.37 2.25 2.17 2.10 2.04 1.99 1.92 1.84 1.75 1.70 1.65 1.59 1.53 1.47 1.39
0

1
2 3.92 3.07 2.68 2.45 2.29 2.17 2.09 2.02 1.96 1.91 1.83 1.75 1.66 1.61 1.55 1.50 1.43 1.35 1.25
0

3.84 3.00 2.60 2.37 2.21 2.10 2.01 1.94 1.88 1.83 1.75 1.67 1.57 1.52 1.46 1.39 1.32 1.22 1.00

23