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Fluid-Elastic Instability in A Tube Array Subjected To Uniform and Jet Flow PDF
Fluid-Elastic Instability in A Tube Array Subjected To Uniform and Jet Flow PDF
Introduction way between tube rows. This heat exchanger had an in-line tube
pattern with a transverse pitch ratio of 1.8 and a streamwise pitch
It is well known that bundles of tubes, such as those used in
ratio of 2.2. It was speculated that the jet from the soot blower
boilers and heat exchangers, can be excited to vibrate excessively
caused fluidelastic instability with amplitudes sufficient to cause
when exposed to a fluid cross-flow. At relatively low cross-flow fatigue failures in a matter of a few hours. However, to the au-
velocities, small amplitude random vibrations occur due to turbu- thors’ knowledge, no study is available in the open literature
lence, and these are usually of little concern from the point of which indicates the effect of a localized jet on the fluidelastic
view of tube life. At sufficiently high flow velocities, these ran- instability of a tube array. The vast majority of the fluidelastic
dom vibrations give way to large amplitude periodic vibrations at instability data in the literature has been determined using labora-
the natural frequencies of the tubes. This phenomenon is known as tory models of single span tubes subjected to a uniform flow ve-
‘‘fluidelastic instability’’ and it is of great concern to plant opera- locity across their spans. Some work has been done on multiple
tors since it may cause rapid failure of the tubes through fatigue or span tube arrays and the effects of partial admission 共i.e., nonuni-
fretting wear at points of contact between adjacent tubes or be- form velocity distribution兲. See for example, Weaver and Goyder
tween tubes and their supports. The onset of the large amplitude 关8兴 and the references in that paper. However, none of these can be
vibrations is usually quite abrupt when the cross-flow velocity related directly to the effects of a localized jet issuing down a tube
through the tube bundle is increased above the so-called ‘‘critical lane where the flow is essentially over one side of the tubes.
velocity.’’ Since tube failures due to fatigue or fretting wear com- The purpose of this paper is to present the results of a study
monly occur at flow velocities exceeding the critical velocity, ac- designed to explain the observed tube failures. A wind tunnel
ceptance criteria for tubular heat exchangers require that the flow model was developed with a tube array geometry that scaled the
velocities never exceed the critical velocity for a particular tube heat exchanger array geometry in question exactly. Two series of
bundle. There are a number of excellent references which discuss tests were conducted. In the first test, the tube bundle was sub-
flow-induced vibrations in heat exchanger tube arrays and specifi- jected to a uniform cross-flow of air, while the tube response was
cally fluidelastic instability, such as by Au-Yang 关1兴, Blevins 关2兴, monitored with a dynamic signal analyzer. This initial test was
Chen 关3兴, Paı̈doussis 关4兴, Pettigrew and Taylor 关5兴, Price 关6兴, and designed to establish a datum case of tube vibration response un-
Weaver and Fitzpatrick 关7兴. der ‘‘uniform flow’’ conditions, which would be used as a basis
The present study was motivated by the catastrophic failure of for comparing with the subsequent tests where the tube bundle
tubes in a large heat exchanger. A second row tube parted com- was subjected to a concentrated ‘‘jet-flow’’ of air. By considering
pletely from its header while several neighboring tubes suffered the jet velocity profile and the partial admission factor, the flu-
fatigue cracks. Visual observations indicated tube scouring at the idelastic threshold of tubes subjected to the jet flow could be
location of a soot blower which had become parked for several predicted reasonably well. While the results have obvious value in
hours. Figure 1 shows a schematic illustration of a steam soot terms of explaining the case history in question, they are also of
blower and its normal path through the heat exchanger. From generic interest in that they bring to light an hitherto unknown and
photographs of the failed tubes, the scouring indicated that the jet potentially dangerous phenomenon.
from the soot blower was directed normal to the tube axes, mid-
Apparatus
Contributed by the Pressure Vessels and Piping Division for publication in the
JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received by the PVP
A model tube bundle and test section was designed and built for
Division September 29, 2003; revision received November 11, 2003. Associate Edi- McMaster University’s 2 ft wind tunnel. The tube layout geometry
tor: M. J. Pettigrew. and the mass-damping parameter were in the range of heat ex-
Journal of Pressure Vessel Technology Copyright © 2004 by ASME MAY 2004, Vol. 126 Õ 269
Parameter Quantity
tube diameter, D 0.0254 m 共1⬙兲
tube length1兲, L 0.619 m 共24.25⬙兲
tube natural frequency2兲 共1 st mode兲, f 12.6 Hz
effective tube lineal mass, m 0.161 kg/m
tube damping ratio 共tube D3兲, 1.1%
air density, 1.19 kg/m3
critical gap flow velocity, V g 7.8 m/s
mass damping parameter, m ␦ / D 2 14.4
critical reduced gap flow velocity, V red 24.3
Connor’s constant, K 6.4
Notes:
1兲
Portion of tubes exposed to the uniform flow of the wind tunnel.
2兲
To achieve the desired stiffness, tubes are mounted on cantilever support rods 共see
Fig. 2 Tube bundle layout and nozzle location Fig. 3兲.
冑
stable and have higher stability thresholds than tubes deeper in the
bundle. The vibration amplitudes generally increased for tubes Vg 共 2 兲 m
⫽K , (3)
deeper in the bundle. The fluidelastic threshold is the point at fD D2
û avg⫽
2
R 2o
冕 0
Ro
û 共 r 兲 rdr⫽0.635. (4)
equivocally that the tube failures experienced in the heat ex-
changer being simulated could not have been caused by normal
operating conditions.
The approximate mode shape for the lowest transverse mode of 2. When the tube bundle was subjected to the concentrated jet
the flexibly mounted tube is, (z)⫽z/L, where z is the axial of air issuing down a tube lane, fluidelastic instability occurred for
coordinate and L is the tube length. This arises from the fact that the 1 st, 2 nd, and 3 rd row tubes adjacent to the jet. This occurred
most of the bending occurs in the threaded rod support while the when the jet flow velocity was sufficiently high and when it was
acrylic tube remains relatively straight due to its greater rigidity. parked in one position for some time. However, if the air jet was
The equivalent nondimensional uniform velocity of the jet flow continuously translated from side to side, so that it did not issue
can be calculated by integrating the average jet flow velocity continuously down a single tube lane, then fluidelastic instability
times the tube mode shape as follows: did not occur. Thus, normal soot blower operation is not expected
冋冕 册
to cause fatigue failure of the tubes due to fluidelastic instability
1
冕 0.96L
0.88L
û 2avg 共 z 兲 2 dz
0.5 but soot blowers should never be operated continuously at a fixed
location in a tube bank.
3. The fluidelastic threshold of a transversely impinging jet
V pn ⫽ L
⫽0.143 (5) flow was estimated by considering the concentrated jet as a partial
2
共 z 兲 dz
2 admission flow, and determining an equivalent uniform flow. In
0 this case, the equivalent uniform flow velocity at the onset of
fluidelastic instability was determined to be somewhere in be-
The expression in Eq. 共5兲 is essentially the partial admission fac- tween 7.6 and 8.6 m/s, which brackets the critical velocity mea-
tor, but in this case the 1/2 term is necessary because the jet flow sured in the uniform flow tests.
acts only on one side of the tube as opposed to both sides as
occurs under uniform flow conditions 共see Lever and Weaver
关11兴兲. The integrand in the numerator of Eq. 共5兲 is taken from 0.88 Nomenclature
L to 0.96 L 共i.e., from a to b shown in Fig. 9兲 which corresponds C ⫽ coefficient of air jet velocity profile 兵—其
to the nominal diameter of the jet acting near the free end of the D ⫽ tube diameter 兵m其
flexible tube. Finally, the equivalent uniform velocity of the jet f ⫽ frequency of vibration 兵Hz其
can be calculated by multiplying the measured core velocity times L ⫽ tube length 兵m其
the partial admission factor, V pn . This calculation is performed K ⫽ Connors’ constant 兵—其
below for two cases: the measured sub-critical jet flow of 53 m/s m ⫽ tube lineal mass including added fluid mass 兵kg/m其
and the measured post critical jet flow of 60 m/s, mt ⫽ tube lineal mass 兵kg/m其
PT ⫽ transverse pitch ratio 兵—其
sub-critical flow velocity: V eq ⫽53 m/s⫻V pn ⫽7.6 m/s r ⫽ radial coordinate of air jet 兵m其
Ro ⫽ nominal core radius of air jet 兵m其
post-critical flow velocity: V eq ⫽60 m/s⫻V pn ⫽8.6 m/s V avg ⫽ average flow velocity in the gap between tubes 兵m/s其
(6) V eq ⫽ equivalent uniform flow velocity for the onset of flu-
idelastic instability for a jet flow 兵m/s其
The results of Eq. 共6兲 agree fairly well with the critical velocity Vg ⫽ flow velocity in the gap between tubes 兵m/s其
measured from the uniform flow tests as shown in Fig. 4. The Vu ⫽ upstream flow velocity 兵m/s其
estimated sub-critical jet flow corresponds to an equivalent flow V pn ⫽ equivalent non-dimensional uniform velocity of jet
velocity of about 7.6 m/s, which resides in the stable vibration 兵—其
region of Fig. 4, while that of the post-critical jet corresponds to û(r) ⫽ non-dimensional radial jet velocity profile 兵—其
8.6 m/s which is above the critical velocity shown in Fig. 4. It û avg ⫽ non-dimensional average jet velocity in the core area
should be noted that there is an estimated error of ⫾10% in the 兵—其
measured centerline jet velocity. Moreover, some of the flow in x ⫽ axial distance from tip of air nozzle to tube 兵m其
the jet core overlaps the tube surface, and this flow would neces- z ⫽ axial coordinate of tube 兵m其
sarily pass through the tube gap thereby increasing the average ␦ ⫽ logarithmic decrement damping 兵—其
flow velocity, V pn , by a small amount. This effect has not been ⫽ damping ratio 兵—其
accounted for in this analysis, but it would serve to increase the ⫽ fluid density 兵kg/m3其
velocities calculated in Eqs. 共6兲 slightly. (z) ⫽ transverse mode shape of tube 兵—其
⫽ standard deviation of velocity profile of air jet 兵—其
Conclusions ⫽ dimensionless radius of air jet, r/x 兵—其
Flow-induced vibration experiments were conducted in a wind
tunnel to determine the critical flow velocity and Connors’ con- Subscripts
stant of a model heat exchanger tube array. Experiments were also cr ⫽ critical value at the fluidelastic threshold
performed on the model bundle to test the tube stability against a g ⫽ quantity measured in the gap between tubes