Flow Induced Vibrations in Boiler Systems

With Low NOx Burners

By
Mark A. Tarbet, P.E.
Senior Engineer
Mechanical & Materials Engineering
Austin, TX 78759

Background

In an effort to reduce acid rain and air pollution such as photochemical smog, boiler manufacturers and
other suppliers have developed burners that can greatly reduced the production of nitrogen oxides (NOX).
These burner systems are being supplied with new boilers and retrofitted to existing boiler configurations.
Problems with abnormal vibrations in various boiler system components and high operating noise levels are
being experienced on some boilers after installation of these new burner designs. An investigation of these
vibrations and noise problems requires sufficient data to determine the cause and implement a repair.

The primary way to achieve low NOX is to create a fuel rich (or low oxygen) combustion process that
increases the combustion temperatures and reduces the formation of NOX. There are several different
designs being implemented, some use sophisticated swirl plates to create flame vortexes allowing more
complete combustion of the fuel. Others incorporate a sophisticated windbox design that requires multiple
air supply streams from various air handling systems to form high temperature flames. Different burner and
boiler system designs are required based on the type of fuel used, where even different grades of coal can
effect the operation of the burner system. The requirements and sophistication of the burner design to
achieve low NOX levels can easily result in problems, such as high vibrations and noise amplitudes of boiler
system components. These components include the various fans (forced draft, induced draft, primary air,
and seal air) associated with combustion air flow, duct work between the fans and boiler, windbox or burner
housing, furnace, superheater, reheater, and economizer sections.

Flow Induced Vibrations

A primary source of noise and vibrations in boiler systems is produced by local component excitation due to
turbulent flow in the duct or other boiler component. The turbulent flow is produced when the profile of the
component changes sharply, such as a transition from a square duct to a rectangular duct or at a transition
exit. This turbulent flow can produce high panel vibrations at a panel resonance frequency. The turbulent
flow can be minimized by installation of vertical and horizontal guide vanes inside the duct. This type of
problem would produce a vibration at a near constant frequency but at varying amplitudes depending on the
flow rate and turbulence.

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 Turbulent flow inside the furnace produced by low NOX burners may also result in vibrations of the tube
walls and other tube sections of the boiler. Burners using swirl plates creating high flow vortexes enter the
boiler furnace in a turbulent condition. Boilers retrofitted with low NOX burners may encounter difficulty
due to the change in flame placement inside the furnace. This can also cause overheating of superheater
tube sections or produce a buildup of slag. This type of vibration would also be at a constant frequency
with varying amplitudes

Another possible source of windbox vibration is turbulent flow caused by excitation from vortex shedding
over internal circular surfaces (tubing). Duct flow velocities may be sufficient to allow turbulent vortices to
form behind circular structures located in the flow path. Flow rates encountered in field tests would
produce vortex shedding frequencies in the duct if the correct size tubing were present inside the duct or
windbox. The vortex shedding frequency is proportional to the flow velocity over the diameter tube
indicated and would change with the increase in flow velocity as the load is increased. High amplitude
vibrations can be produced by vortex shedding frequencies if the resonance frequency of the tube producing
the vibration is within 20% of the shedding frequency. The vortex shedding frequency can then “lock-in” to
the tubing natural frequency and the vibration level grows depending on the flow velocity and the damping
present in the tubing system.

Standing acoustic waves with peak frequencies based on dimensions are another possible source of
vibration and noise. Again the primary excitation force of most boiler system problems is flow excitation,
which generally produces a change in peak frequency and amplitude as the boiler load changes. The two
primary parameters that change are the flow velocity through the duct (which can increase over 100%) and
the static pressure (which can increase over 200%) from low load to full load operation.

Boiler System Testing and Analysis

Boiler Test Setup

In order to determine the source of unusual noise and vibration, measurements must be made to document
the response of each boiler system under various operating conditions. A test plan should be formulated to
ensure that plant management, operations, and maintenance staff can provide operating conditions
necessary for data collection. The control of boiler load will be required and the boiler operated from no
load to a maximum load condition. Operational changes and holds at various load settings should be
scheduled with sufficient time intervals to allow the vibrations to stabilize and collect data. Communication
between operations and testing personnel will ensure data is collected at the appropriate conditions and that
the boiler changes are kept on schedule. Documentation of all key boiler parameters is required and can
usually be programmed into the plant control system and downloaded onto a disc in a standard text format
for post processing.

Preliminary Analysis
A preliminary vibration survey using portable data acquisition equipment at conditions where high
vibrations are encountered will allow for the correct placement of multiple vibration sensors and
microphones during a formal test. This survey of vibration and noise data should include data acquisition at

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 various positions and directions to create an amplitude map of structural components. Various techniques
and parameters should be used including Fast Fourier Transform (FFT) spectral analysis of the acceleration
and noise data to determine amplitudes and frequencies at key locations.

Operational Testing
The continued development of multi-channel data acquisition systems with virtual real time collection
provides the capability to document the operating condition of boilers equipped with new burner designs.
Systems with multiple simultaneous data acquisition channels allow for the direct comparison of vibration
frequencies from sensors located on various boiler system components. These systems also provide the
capability to track specific frequencies, such as component resonance frequencies, or peak amplitudes that
change frequency as the load changes.

A typical test setup includes mounting temporary accelerometers on the fans, transition pieces or control
vanes, ductwork, windbox or burner housing, boiler frame, furnace walls, or other vibrating surfaces.
Magnetic mounts are usually acceptable since flow related frequencies occur below 200 Hz. A surface
temperature reading is useful to ensure the accelerometer is capable of handling the exposure to hot areas.
Standard and low frequency accelerometers are typically used, where normal accelerometers are rated for
frequencies from 2 Hz to 7,000 Hz and the low frequency accelerometers have a range from 0.5 Hertz to
2000 Hz. The analog signals should also recorded on a digital or analog tape recorder to provide the ability
to analyze the data further if necessary without repeating the test.

An impact hammer and accelerometer should be used at various locations on the boiler system components
to determine natural (or resonance) frequencies of large area panels. Ideal conditions would be to perform
the testing while the unit is shut down, but some testing can be performed on-line if necessary.

Case History 1: Noise and Vibration of 100,000 lb/hr Boiler

Background
During a plant upgrade of a chemical process plant, old boilers were replaced with new natural gas fired
units rated to generate 100,000 pounds of steam per hour (lb/hr). The new boilers were equipped with a
single low NOX burner and were connected to the existing forced draft (FD) fans, ductwork, and exhaust
systems. The boilers are located adjacent to each other inside an enclosed building, which also housed the
control room. Other improvements included re-rating the fan by adding tips, installing an exhaust gas
recirculation line, and a new common stack. During the initial startup and operation of the boiler, a loud
noise was noticed in the control during certain modes of operation. An even more important fact was the
boiler could only reach about 75% of rated capacity. Initially plant personnel thought the low NOX burner
was the cause of the noise and operating problems due to the fact that the burner fuel supply piping vibrated
noticeably during low load conditions when the noise was the loudest.

Vibration and Noise Analysis

To determine the source of the noise and vibration, temporary accelerometers were magnetically mounted at
various locations around one of the boilers to measure the vibration levels during a load ramp test.

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 Vibration data were collected from 14 locations including the burner, boiler, FD fan, and inlet duct system.
Table 1 lists the vibration data collection points, which are indicated by arrows in Figures 1 and 2. A
microphone was used to collect narrow-band airborne sound data near the burner as indicated by the large
arrow (location 15) shown in Figure 1.

The vibration and sound data were continuously monitored and recorded while the boiler load was ramped
from 16,600 lb/hr to a maximum obtainable load of 72,600 lb/hr. The load increase took approximately 45
minutes to complete. The load was held at 72,000 lb/hr for a short period then reduced to a minimum load
of 26,000 lb/hr.

The maximum vibration amplitude measured during the test occurred on the side of the FD fan inlet duct
(location 13) shown in Figure 2. Figure 3 shows the spectral waterfall plot and vibration overall amplitude
trend plot collected from this measurement point during the load ramp testing. This plot shows maximum
overall amplitude vibration of 5.5 g’s pk at all boiler load levels below 42,000 lb/hr. The plot in Figure 4
displays the primary peak vibration amplitude of 2.0 g’s pk at a frequency of 21 Hz, plus noticeable peaks
at frequencies corresponding to harmonic frequencies of 21 Hz. Figure 5 is sound data collected at location
15 near the burner at a load of 29,000 lb/hr. This also indicates a narrow band un-weighted noise level of
112 dB at a frequency of 21 Hz. Vibration amplitudes from the remaining sensors showed the next highest
amplitudes of 1.0 g’s peak on the FD fan inlet and 0.5 g’s pk on the FD fan flow control, also with a
maximum peak at a frequency of 21 Hz.

The vibration amplitude of the inlet duct decreased suddenly to less than 0.5 g’s pk amplitude when the
boiler load exceeded 43,000 lb./hr. This was accompanied by a shift in the vibration frequency from 21 Hz
to 28 Hertz as the load increased from 43,000 to 71,000 lb/hr.

Vibration data collected from the motor indicated the maximum vibration amplitude frequency to be 30 Hz,
which corresponds to the motor running speed of 1800 rpm. The motor and fan bearing pedestal vibrations
were low at all operating levels and were considered to be in good mechanical condition and not the source
of vibrations. Vibration spectral data collected from the fan also displayed a peak at 300 Hz, which
corresponded to a vane pass frequency for fans with 10 blades.

Bump test data collected from the duct while the unit was on-line showed a side panel natural frequency of
79 Hz. The natural frequency of the duct inlet was determined to be 59 Hz. This indicates the duct
vibrations are not a result of excitation of structural natural frequencies.

Summary
The high amplitude 21 Hz duct vibration levels and noise occurred when the boiler load was below 42,000
lb/hr. It was noted that during this load range, flow control dampers located in the fan inlet duct (both
before and after a flue gas recirculation line) were either fully closed or nearly closed. Since the fan is
constant speed these dampers are used as part of the boiler load control. The dampers remained almost
closed while the boiler fuel was increased to increase the load to 43,000 lb/hr. The high amplitude 21 Hz
noise and vibration measured on the inlet duct was occurring near 70 % of fan running speed during that

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 time period, indicating the fan was operating in a stall condition. Stall usually occurs near 66% of fan
running speed, but can occur from 60 to 70 % of fan running speed. Another indication of fan stall is
vibration peaks at harmonics of the stall frequency (i.e. 42 Hz, 63 Hz, 84 Hz, etc.), of which all were
present on the duct during low load operations.

Rotating stall of centrifugal fans generally occur when the inlet conditions are not adequate, such as
inlet/shroud clearances, inlet flows, and inlet damper settings. Stall can produce a flow reversal in the inlet
resulting in low frequency pressure pulsation in the inlet duct, which can produce duct vibrations similar to
those present on this system. The inlet ducts open up inside the enclosed building and the 21 Hz pulses
were being transmitted to the control room window.

It would appear that the FD fan is overrated, since the inlet dampers were almost closed during low load
operation. However, the FD fan on each boiler must be able to supply 37,500 cubic feet per minute (CFM)
at 22.47 inches of water gauge (IWG) pressure in order for the boiler to reach 100,000 LB/hr. Adding head
losses to the maximum rating point on the original fan curve yielded a maximum supply of 36,039 CFM at
22.30 IWG, or not enough to reach maximum load. In order to solve both problems, the fan was modified
again and equipped with a variable frequency (speed) drive on the motor. This allowed for the fan
operation with adequate air supply at all operating conditions and increased flow to reach maximum load
conditions.

Table 1 – Boiler #2 Vibration Measurement Points

Sensor Description Direction Sensor Type

1 Burner Axial Low Freq. Acc.
2 Boiler Frame (Front left side) Vertical Accelerometer
3 Boiler Frame (Front left side) Horizontal Accelerometer
4 Boiler Frame (Front left side) Axial Low Freq. Acc.
5 FD Fan Frame (Half way up front left side) Vertical Accelerometer
6 FD Fan Frame (Half way up front left side) Horizontal Accelerometer
7 FD Fan Frame (Half way up front left side) Axial Low Freq. Acc.
8 FD Fan Frame (Half way up front left side) Horizontal Accelerometer
9 FD Fan Motor Inboard Radial Accelerometer
10 FD Fan Motor Inboard Axial Accelerometer
11 FD Fan Housing Inboard (Center) Axial Low Freq. Acc.
12 FD Fan Flow Control Vanes (Fan Side) Horizontal Low Freq. Acc.
13 FD Fan Duct (opposite side from recirc.) Horizontal Low Freq. Acc.
14 FD Fan Fresh Air Inlet Horizontal Accelerometer
15 Burner Sound Axial Microphone

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 Figure 1. Boiler Vibration and Sound Measurement Locations

Figure 2. FD Fan and Inlet Duct Vibration Measurement Locations

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 Figure 3. FD Fan Duct Vibration Waterfall Plot - Load Ramp Testing

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 Figure 4. FD Fan Duct Vibration Spectra - Load Ramp Testing

Figure 5. Burner Sound Levels at 29,000 lb./hr Load

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 Case History 2: 300 Mlb./hr Boiler System

Background
High vibration and noise were reported on the inlet duct that delivers air from a forced draft (FD) fan to a
water tube, natural circulation, two drum Stirling type power boiler. The boiler is natural gas fired with six
burners and produces 380,000 lb./hr (380 Mlb/hr) steam flow while operating at 100% load. Ambient air
from the forced draft fan is directed through a duct into the windbox, where it is distributed to the burners.
The duct shown in Figure 6 consists of a transition from the fan outlet, the duct itself, including internal
flow guide vanes and a 90 degree turn up into the windbox. The duct is constructed of carbon steel plate
and originally had 3” angle iron stiffeners.

The objective of the testing was to measure the vibration amplitudes on the boiler inlet duct and determine
the source and severity of the vibration and noise. The testing was conducted after a web of 8” by 3/8” steel
I-beam was welded to the top and bottom of the duct and internal pipes were installed between the sides in
an attempt to reduce vibration amplitudes. Plant personnel had reported vibration amplitudes in excess of
2.0 inches per second peak amplitude at various loads and locations on the duct after the modifications.
The boiler OEM reported different maximum amplitudes at different load levels.

Vibration Data Analysis

Vibration data were collected from the FD fan, transition, duct, and windbox using a portable data collector
while the unit was operating in a steady state condition of 300 Mlb/hr. The maximum overall vibration
amplitude of 1.96 ips pk was measured on the side of the transition at the center of a panel in the horizontal
direction (Position 2 in Figure 7). The vibration spectrum indicated the primary peak of 0.8 ips at a
frequency near 39 Hz. The duct top section (Pos. 6) displayed 0.8 ips pk measured at the center of the
panel in the vertical direction. The vibration spectrum for this location indicated the maximum peak
amplitude of 0.23 ips at a frequency of 27 Hz. The vibrations measured on the side of the transition and top
of the duct were typical of the vibration amplitudes measured by plant personnel prior to this test.

Bump tests were performed on the duct and windbox to determine the natural frequencies of the panels.
The data showed that the lowest natural frequency of 27.5 Hz occurred on the top horizontal panel of the
windbox. The transition side and top panels showed a minimum natural frequency of 37.5 Hz. The duct
displayed a minimum natural frequency of 47.5 Hz on a side panel and 68.8 Hz on a top panel.

A load ramp test was conducted where the boiler load was varied from a minimum load of 250 Mlb/hr to
380 Mlb/hr. The vibration data were monitored continuously and recorded during the load ramp test. The
maximum vibration amplitude measured during the load ramp test occurred unexpectedly on the top panel
of the windbox in the vertical direction. This vibration reached amplitudes of 8.0 ips pk between boiler
loads of 290 MLB/hr and 360 MLB/hr. Figure 8 shows a trend plot of the boiler load, maximum peak
amplitude, and maximum peak frequency measured during the load ramp test. The analysis software was
used to track the peak amplitude, which also had a varying frequency. This plot shows a frequency shift
from 16.5 Hz at 250 MLB/hr to 22.5 Hz at 380 MLB/hr, with the maximum peak of 8.0 ips pk (150 mils
peak-to-peak displacement) occurring at a frequency of 20.5 Hz and a load of 330 MLB/hr. Figure 9 shows

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 a spectra waterfall plot of the windbox vibration during the load ramp test. The changing frequency of
vibration verifies that the high amplitude vibrations vary with flow and pressure in the duct system. The
vibration frequency change of approximately 36% is almost directly proportional to the increase in velocity
inside the duct system. Vortex shedding was first considered as a source of flow induced vibration but 3”
diameter piping would be required inside the windbox to produce the desired frequencies

Summary
The transition piece and duct panel vibrations on both the side and top displayed maximum peak vibration
amplitudes at frequencies corresponding to resonance frequencies recorded during the bump tests. The
primary source of side and top panel vibration was turbulent flow of the air at the FD fan exit and at the
entrance of the duct from the transition. The vibrations measured from the side panel after the guide vanes
(where the air flow is more laminar or less turbulent) do not display these high amplitude vibrations at the
panel resonance frequencies. Based on maximum vibration amplitudes collected from the duct and
transition, the panels should not fail by exceeding the fatigue endurance limit; however, a recommendation
was made to install vertical flow guides inside the duct to reduce the turbulent flow and/or install additional
stiffeners on the flat panels. The plant attached schedule 80 pipe in an X configuration on the flat panels
and the maximum vibration was reduced from 2.0 ips pk to 0.4 ips pk amplitude at full load.

The maximum vibration amplitude of 1.4 ips pk at a frequency of 109 Hz was measured at the center of a
duct top panel in the vertical direction during low load operation of 250 MLB/hr. The 109 Hz vibration
peak drops out as the load approached 300 MLB/hr. As the load continued to increase, a high amplitude
vibration (excess of 1.0 ips pk) appeared at very low frequencies near 2 Hz. This low frequency vibration
increased as the load increased and maximum amplitudes were measured at 380 MLB/hr. A strong
vibration peak at a frequency of 2.5 Hz and its harmonic frequencies (5.0 and 7.5 Hz) was also detected on
the spectrum analyzer during full load periods. Post test calculations revealed the duct cross section yields
an acoustic resonance frequency of 2.6 Hz. The vertical flow guides recommended to reduce the internal
turbulent flow should also eliminate the acoustic resonance of the existing duct.

Plant personnel reported cracking at the top of the windbox where it connects to the boiler but were not
aware of the high vibrations or cause of failure. Three of five identical boilers experienced 5 failures in 6
months of operation on the top section of the windbox. Assuming an allowable endurance limit stress for
carbon steel of 13,000 psi zero to peak, a safety factor of 1.3, and a stress concentration factor of five (at the
heat affected zone of the weld), the allowable stress would be 2000 psi. Calculating the stress from the
maximum plate deflection of 150 mils pk-pk measured on the top of the windbox during the testing period
resulted in a value of 1982 psi, which means the current maximum vibration levels are right at the limit of
acceptability. This does not take into account variations in stress concentration factors for welds and other
anomalies. It also does not reflect repeated instantaneous vibration excursions over 8.0 ips pk, which were
visually noted on the spectrum analyzer during the load ramp testing. The windbox vibration is attributed to
burner pulsation caused by dead spaces in the furnace. This occurs when the burner flame length either
does not reach the full volume of the furnace or overshoots leaving voids in the combustion area.

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 Figure 6. Overview of System

Figure 7. Duct Vibration Measurement Locations

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 Figure 8. Windbox Vibration Frequency Track – Load Ramp Test

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 Figure 8. Windbox Vibration Waterfall Plot – Load Ramp Test

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