Experimental Studies and Controller Design of Shell and Tube Heat Exchanger Using With and Without Insert

An experimental study of heat transfer characteristics with and without insert was found using water –water system on 1-2 pass shell and tube heat exchanger. Experimental results such as exchanger effectiveness, overall heat transfer coefficient were calculated using with and without insert. There is improvement in overall heat coefficient, efficiency in using twisted tape. In all the process industries the process variables like flow, pressure, level and temperature are the main parameters that need to be controlled in both set point and load changes. The transfer of heat is one of the main important operation in the heat exchanger .The transfer of heat may be fluid to fluid, gas to gas i.e. in the same phase or the phase change can occur on either side of the heat exchanger. . The control of heat exchanger is complex due to its nonlinear dynamics. For this nonlinear process of a heat exchanger the model is identified to be First Order plus Dead Time (FOPDT). The conventional controller is designed in both with and without insert and compared with IMC based-PI controller based on settling time ,rise time and it found to be IMC suitable for heat exchanger than the conventional PI tuning.