aN Proceedings of PVP2005 2005 ASME Pressure Vessels and Piping Division Conference July 17-21, 2005, Denver, Colorado USA PVP2005-71661 Acoustic Vibration Behavior of Full Size Steam Generator and Tubular Heat Exchanger In-Line Tube Banks- -A Brief Note Frantisek L. Bisinger Robert E. Sullivan, Consultants ABSTRACT Based on recent laboratory experimental data by Feenstra et al. {1],2] it has been determined that for larger test section widths, the maximum acoustic pressures generated during acoustic resonance were greater by more than a factor of four than those predicted by Blevins and Bressler [3]. We have evaluated a great number of resonant and non-resonant cases from inservice experience of full size steam generator and tubular heat exchanger tbe banks in order to see the genera} vibratory behavior of the full size units. Fifteen vibrating and twenty-seven non- vibrating cases were evaluated and compared to the Feenstra etal, relationship. It is shown that on average the results from the full size units correlate well with the Feenstra et al. relationship, A_gap exists between the vibratory and the non-vibratory cases, The non- vibratory cases produce acoustic pressures which ate at or below the Blevins and Bressler relationship. From the results it can be concluded that the full size units, regardless of their size and also acoustic mode, produce high acoustic pressures at resonance, with the ‘maximum acoustic pressure on average more than fifty to seventy five times higher than the input energy Parameter defined by the product of Mach number and pressure drop through the tube bank. The results are tabulated and plotted for comparison. NOMENCLATURE = tube outside diameters = acoustic frequency Mach number = umber of tubes deep in low direction = maximum acoustic RMS pressure pressure drop through tube bank = Stroutal number for tube bank zZz79 og W flow channel width % = TID =tranverse tube spacing ratio x = LID = Tongitudinal tube “spacing ratio LABORATORY SCALE MODEL TESTS EXPERIMENTAL DATA. Laboratory scale model tests were performed by Feenstra ct al. (1, (2] for three different test section widths of 505 mm, 714 mm and 953 mm, The tube bundle consisted of 19.1 mm tubes of a staggered arrangement with a transverse tube pitch of 30.0 mm and a longitudinal tube pitch of 20.6 mm. The tube bundle consisted of 15 tube rows in the streamwise direction. ‘The tube bundles were placed in a flow channel within which they were exposed to air flow at ambient temperature The baseline measurements were made in a straight through flow channel with a channel width of W=714 mm with the tube bank fully extended side- to-side, Follow-up measurements with an enlarged channel width of W = 953 mm also fully filled with tubes side-to-side and a reduced width of W = 50S mm also fully filled with tubes side-to-side were made utilizing a smooth transition duct section. In all the three cases, the depth of the tube bundle in the flow direction remained the same. The onset of acoustic resonance was carefully controlled relative to flow velocities, acoustic pressures, acoustic mode and frequency. Most importantly, the acoustic Frequencies at resonance were consistent with the tested channel widths in all three tested cases. The test results were given in Feenstra et al. [1] showing the results forthe three tested section widths together with the data of Blevins and Bressler [3}, ' Copyright © 2005 by ASMEwhich were obtained using a test section wideh of W = 457 mm, Figure 1 taken from Feenstra etal (2] gives the ‘summary of the laboratory scale madel tests for the three different test section widths of 505 mm, 714 ‘mm and 953 tom it relation tothe relationship of Blevins and Bressler (3). The test points are ‘numbered according to the acoustic mode number for each case. Also superimposed in this figure are the results of Ziada etal, [4] who used test section widths (of 375 mm and 450 mm, and Fitzpatrick and Donaldson (5] using a test section width of 200 mm. From the results it can be seen that the maximum acoustic pressures at the onset of acoustic resonance at modes | and 2 for the wider test sections (714 mm. and 953 mm) are much greater (more than 4 times. greater) than those predicted by the Blevins and Bressler relationship [3] which was obtained using a test section width of 457 mim. For higher modes, the acoustic pressures become relatively lower, approaching those predicted by Blevins and Bressler FULL SCALE STEAM GENERATOR AND ‘TUBULAR HEAT EXCHANGER TUBE BANKS, ‘Table | gives the resonant acoustic parameters for & number of vibrating tube banks of full scale units bbased on inservice experience (most of the data are taken from Fisinger et al.{6)). Table 2 lists similar parameters for non-vibrating or non-resonating full size steam generator tube banks also from inservice experience [6]. All of the fall scale data represent the ‘acoustic parameters of straight through rectangular flow channels of different sizes containing the tube banks with the tube banks fully extended from sidewall to sidewall of the flow channels in all the cases, Figure 2 shows a plot of the Table 1 and Table 2 data in relation to the Blevins and Bressler [3] relationship of P= 12.5 Map where P is the maximum RMS acoustic pressure in Pascals, M is the crossflow Mach number and. Ap is the pressure drop through the tube bank in Pascals, ‘The solid symbols represent the fifteen vibrating or resonating tube banks specified in Table 1 and the open symbols represent the twenty seven non- vibrating or non-resonating tube banks specified in Table 2 From the results we can see that the maximum ‘acoustic pressures for the vibrating, units congregate much above the Blevins and Bressler relationship from ‘a minimum of 17.9 MAp_in case 6 to @ maximum of 214.7 Map in ease 15. ‘The mean (average) value of all the 15 cases is 76 MAp, or 6 times higher than the value given by Blevins and Bressler. It can also be seen that on average the full size data correlate well with the data of Feenstra et al All the non-vibtatory cases ate at or below the Blevins and Bressler relationship, DISCUSSION ‘The purpose of this brief note is to emphasize that full size units produce much higher acoustic pressure levels during acoustic vibration than the results ‘obtained by the typical narrow section laboratory experiments. The primary source of the narrow section laboratory data are those of Blevins and Bressler [3] who used a test section width of 437 mm. Feenstra et al. (1}{2] used wider test sections of 714 mm and 953 mm and it was shown in these tests that the acoustic pressure levels at acoustic resonance ‘were much higher than those ob\ained by Blevins and Bressler [3]. These test results indicate that the test section width clearly plays a role in the devetopment of the acoustic pressure levels at acoustie resonatice, ‘A’ natural question arises as to how these laboratory test results relate to large fullsize operating units experiencing acoustic resonance, ‘We have compared a great number of full size steam generator and heat exchanger tube banks, fifteen of which experienced strong acoustie vibration in operation and twenty seven which did not vibrate, with the laboratory experimental results of Blevins and Bressler (3] and Feenstra ota. [1],2). As can be seen from the comparison, the full size units were on average much noisier than the results of | Blevins and Bressler would suggest and matched more closely those obtained by Feenstra et al utilizing the wider test sections, The comparison also showed that the Blevins and Bressler relationship which was obtained to predict maximum acoustic pressures at resonance, actually represents the upper limit of the non-resonating or non-vibrating cases of the full size units, The question arises what causes the large difference between the acoustic levels produced by the vibrating full size units in reference to the small scale laboratory tests. Itis clear that the size of the unit plays a role in increasing the acoustic pressure Tevels due to dynamic magnification and apparently a lower acoustic damping. The larger units need relatively less input energy to produce the acoustic pressures at resonance, Based on the laboratory tests, it was clear that the ‘maximum acoustic pressures became higher (Substantially higher) at increased test section widths, Based on the tests it was not possible to establish an exact relationship between the channel width and the ‘maximum acoustic pressures at resonance. The full scale data which represent a wide range of channel dimensions and also acoustic modes provide evidence that indeed the acoustic pressures establish themselves Copyright © 2005 by ASME.‘at a much higher level, at oF above the level as the test data obtained with the larger test sections. It is also interesting to note that the maximum acoustic pressures occur in the fall scale units at this higher level within 2 large range of the input energy parameter Map. Even at relatively low values of Map, the resonant acoustic pressures are high. It therefore appears that 2 significant magnification of acoustic pressures occurs in the fall scale units the magnitude of which is apparently limited by non- linear effects SUMMARY AND CONCLUSIONS Laboratory experimental tests for acoustic resonance in tube bundles revealed that in wider test sections the maxirum acoustic pressures in the lower acoustic modes occur at P = 534 Map. This is 53.4/12.5 = 4.27 times (or 12.6 dB) greater than the relationship predicted by Blevins and Bresser ‘The evaluated full scale steam generator and tubular heat exchanger units at resonance also produced very high acoustic pressures averaging at about P= 76 MAp, values generally commensurate with the laboratory data using the wider test sections and significantly higher than the values predicted by Blevins and Bressler. Very high acoustic pressures ray generally develop in full scale units at resonance duc to dynamic magnification effects ‘The non-vibratory units are well separated from the vibrating ones with maximum acoustic pressures occurring at or below the Blevins and Bressler relationship. REFERENCES [1] Feenstra, P.A., Weaver, D.S., and Bisinger, FL, 2004, “The Effects of Duct Width and 2) 4) (51 (61 Baffles on Acoustic Resonance in a Staggered Tube Array”, Proceedings of the 8" Intemational Conference on Flow-Induced Vibration, FIV 2004, Editors E. de Langre and F. Axisa, Paris, France, 6-9 July 2004, pp. 459-464. Feenstra, PA., Weaver, D.S. and Bisinger, F.L. 2005 “The Effect of Test Section With fon Acoustic Resoriance in a Staggered Tube Array”, Submitted for Publication, Blevins, R.D., and Bressler, M.M., 1993, “Experiments on Acoustic Resonance in Heat Exchanger Tube Bundles*, J. Sound and Vibration, 164 (3) pp. 503-533, Ziada, S., Dengoren, A., and Bublmann, E.7., 1989, “On Acoustical Resonance in Tube Arrays, Patt 1, Experiments, Part H Damping Criteria”, J. of Fluids and Structures, Vol. 3, pp. 293-324 Fitzpatrick, J.A., and Donaldson, LS,, 1977, “A Preliminary Study of Plow and Acoustic Phenomena in Tube Banks”, ASME J. Fluids Engineering, Vol. 99, pp. 681-686. Bisinger, FL, Francis, 1.7., and Sullivan, RE., 1996, “Prediction of Acoustie Vibration in Steam Generator and Heat Exchanger Tube Banks”, ASME Jounal of Pressure Vessel Technology, Vol. 118, pp. 221-236. Copyright © 2005 by ASMEMaximum Acoustio Pressure, nse (Pa) [re ape 180 40° F E . 4170 resounrcases 3 2 a 2 {160 8 % 3 10° F : ° ie 2 + “A 44 3 x 3/4 é : z ke “ {140 8 y ‘\ fr Pomme = 12.5 * MCP od 108 10° 108 10 10° 10% Input Energy Parameter, MaP (Pa) ‘Blevins & Gresser (1056) prodicton (W= 457 nr) ‘Present data, case 1 (W= 505mm) Present data, case? (W.=714enen) Present data, case 3 (W/= 953mm) ‘Stag. aay, W= 375mm ada et a, 1989) ldrtine aay, WW = 450ren (aka et 1909) levine array, W = 200hn (Ftzpatrick & Donaldson, 1977) Figure 1: Maximum acoustic pressure versus input energy parameter ( Map ) for laboratory experimental data using different test section width. Note that the Mach number, M, corresponds to flow in the gap between tubes. Graph taken from Feenstra et af. [2]. Oo DONX+ 4 Copyright © 2005 by ASMEP.Pa 10000 Ww VaRATION Pu BNO Visrarion| AVERAGE OF VIBRATING UNITS SHOWN. S pessamin FEENSTRA tal (11.12) co 4 Pe r2smao. BLEVINS and GRESSLER (9) 10 100 1000 Map, Pa Figure 2: Maximum acoustic pressure versus input energy parameter ( MAp } for full size vibrating ( Table 1) and non-vibrating ( Table 2 ) steam generator and tubular heat exchanger tube banks. Note that the non- vibrating units are below the Blevins and Bressler relationship while. the vibrating units are well above it and generally congregate around the Feenstra et al. relationship. 5 Copyright © 2005 by ASMETABLE 1: Acoustic Resonance Parameters of Vibating Full Size Steam Geaeiator and Tabular hago n-Line Tube Banks wf. xe NE | Mode [ap Mas |S Pah oy | do ty, x1 |_| | | bn 1987 [oaste | 300 | aoa [ar 1a} 339 Pores [oa7_[ ia [seo 077 ipa [oss [300200 Toa [330 2H [m7 [set oz pws [aan 1 300) 987 [ose 325300 15 [300 Lis} 3234 [$6 asf 40 3000153 196 —[ ones [120 } 200 fa Tass 3a [19555019 [13s] 36671380) ast [0063s [130-130] 1039 336 ooss_[ 7003 [yas | 1067 a3 1575 [ousma [222 [135 | 20 58 462 [ais [reson Puss faa L179 3505 | oosok [278 | 300 16 a9 7 39 [sna aspen bar faerie 3505 [ons p27 f 20 [1a fase 1382 [398 pois [tay | Son | dasa 933 [oom P19 [ 200 [9 fora 269 [air |e Pons Pi faa ia 923 [oom [ 300 [Leo 2ae_[ 9a [ 33 oasf ata 198 [0063s [260 [130 [2 Las 338 [a }s9—[ots Ds [seg 1 269 i [1asT aos | 280 P30 [2 Paso 324 [isos Taat [ong [1917833 | 36 th gar desis | 200 Pa ao at s50 Sm [aea [oat [ania [aarti i596" Toesos [20 Ps Tis Tso. 247 [4080 [100 [oae—[ ss [a0 P89 156 —[aosoe [295 [20 a9 120 266 [1367 fae [02s [153 Pane _P aia ie) “TABLE 2; Acoust Resonance Parameters of Non-Vibraing Full Siw Steam Generator and Tubular Heat Exchanger In-Line Tube Baaks we Ww B = p= ps Wade [ip aay fe cod] tm x10" Pa) Pa) Top e9s_ [ness Tao] Fa Toss as 385 21695 | “aso 137s [ 2 S90 2as Bie 35s [nso 13s [3s 2 |200 [ss | as ise Tsao 2a [20a 398 [oie 36.1 Spas “oosrz 1s] 36 [2st axes 27 [0g Bass [12 | “nos 133] 4 x26 265 19 [0 172 Tf 97 | 00572 3s as Sor [oe 60 3 Pon“ o0sr 2a 2 fsa 9 Sa 08 60.05 [i979 | “o0635 130_| 14 Speer 557 Lao [0 14s Te| 1818 | 00635, 13074 sora i530 376 Tse | 0057 136 Piss Tat [ oe 6 1230 | oes 1335 {| 302926 ssi [on 328 1] 20 [nos 33 [a0 4139s 437 [oe 3a, 1a 1s78 | Das ia 3 [3030] 668 | 01g 37, Hf ise} pasoe ists [6 S| aa [506 236 | 01g 205. is [iso1_} 0635. f30_[ 35 2 22 58 131 Pe 132 17 ieor_| 00635, 13039 3159 762 167 [one BS ia [ ise [ os, 1333 3 3207 eos, 16.5 19 [ists 00655, 130 [a 3 [291 [1780 Sis ors, 469 20 | 18:18 |—posr2 ia [36 3 [26 s46 24s [one 22 Bi [1523] sre tas [sab par i71__| ous, iss 22 | 1529 | 0.0699 12716 4 si [3197 1630.18 1498 23 [1s] posog Bins | 32 > is 482 37 | 018 100 2a | 270s | 0s 13536 3 [ose [ine Tie os, 16.5 25_[-a705 [ose 135 [20) 3 [iss 80 065 [018 #2 36 |~164 [pos 133 [3 x 39 [ar 331 | 00g 319 27 | Asa] 0508 20015 aa tt 198 [02 179 6 Copyright © 2005 by ASME.