Unit Operations Lab Heat Exchanger 

Operating Procedures
Please refer to Figures 2-1 and 2-2 for location of the valves, pipes, switches, and other
equipment on the service and chiller units.
Filling Water Tanks
There are two water tanks in the system: hot water tank on the service unit and the cold water
tank on the chiller. Water circulates in two closed circuits (one for hot water and one for cold
water) and the tanks are filled prior to the class. Therefore, the students should not need to fill the
tanks.
In case the water tanks do need to be filled please follow these instructions:
Hot water tank
a) If the tank is empty: Add water until the low level is reached (level switch trips and the
Low Water Level warning lamp goes out). Then add 0.5 L of water with a beaker.
b) If the tank is filled but with an unknown volume above the low level: Partially drain the
tank using the Hot Water Drainage valve on the service unit until the low level is reached
(level switch trips and the Low Water Level warning lamp lights up). Then add 0.5 L of
water with a beaker.
Cold water tank
Fill the tank until you see water in the sight glass.
Start-up
1. Secure the selected heat exchanger on the base plate of the service unit. Connect the tubes for
the inlet and outlet flows. In addition, for the tubular heat exchanger, connect the temperature
sensors at the midpoint of the heat exchanger to the service unit.
2. Turn on the main switches on the chiller and the service unit.
3. Open the regulator valves V1 and V2 for cold and hot water flow rates on the service unit.
4. Set the desired temperatures Th,i and Tc,i for the hot and cold water feeds using the temperature
setpoint controllers on the service unit (for hot water) and the chiller (for cold water). Turn on
the heater and the chiller and wait until the water temperatures reach the setpoint values.
NOTE: A situation may arise in which temperature of the hot fluid in the tank is higher than
its setpoint value Th,i or temperature of the cold fluid is lower than its setpoint value Tc,i. If
temperature of water in the hot water tank is higher than Th,i, turn the heater off and run the
heat exchanger until the water in the hot circuit is cooled to the desired value. Similarly, if
necessary, warm up cold water to Tc,i by running the heat exchanger while the chiller is turned
off.
5. Turn on the pumps on the service unit and the chiller.
6. If required, bleed the heat exchanger to remove air bubbles trapped in it:
a. Detach the heat exchanger base plate while keeping all tubes connected to the heat
exchanger.
b. Turn the heat exchanger so that water is flowing upwards to push the air out.
c. Reattach the base plate

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Unit Operations Lab Heat Exchanger 

Operating the System

1. Use the regulator valves V1 and V2 to set the cold and hot water flow rates.
2. Monitor the measured temperature values to determine if the steady-state is reached. After the
steady-state is reached, continue measurements for a few more minutes to collect a
sufficiently large sample of data for future statistical analysis. Record and report both the
evolution of the temperatures prior to reaching the steady-state and the magnitude of the
fluctuations of the temperatures at the steady-state.
NOTE: In some cases the chiller may not be able to maintain the setpoint temperature for the
cold water. However, the system should still be able to reach a steady-state with a higher
temperature of water in the cold water tank. In your calculations you should use the actual
(not setpoint) temperature of the feed.
3. Switch to different flow-rates and/or inlet water temperatures. It is recommended to explore
effects of the water flow rates on the system behavior at the current inlet temperatures prior to
changing setpoints for the inlet temperatures. This will minimize the time spent waiting for
cooling/heating water in the supply tanks.
Swapping Heat Exchangers
1. Turn off the pumps on the service unit and the chiller.
2. Disconnect the heat exchanger currently connected to the service unit. To disconnect the
water tubes from the heat exchanger, push or pull the latch located on the connector (whether
it needs to be pushed or pulled depends on the connector type which differs for the hot and
cold flows) and then pull the connector off of the heat exchanger.
3. Secure a new heat exchanger on the service unit and connect all tubes and cables.
NOTE: The connectors on the heat exchangers and the tubes have a locking mechanism
which prevents water from leaking when the tubes are disconnected. This in particular
implies that the heat exchangers will contain water after they are disconnected from the
service unit. This is normal and should not cause problems (unless temperature in the lab
falls below freezing).
Reversing Flow Direction (Parallel ↔ Counter-flow)
1. Turn off the pumps on the service unit and the chiller.
2. Switch the inlet and outlet tubes for either cold or hot water. Follow the directions in Step 2
for swapping the heat exchangers.
Shutting off
1. Turn off the heater and chiller as well as the pumps on the service unit and the chiller.
2. Close regulator valves V1 and V2.
3. Turn off the main switches on the service unit and the chilling system.

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