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    24 views6 pages

    Vibration Analysis

    Uploaded by

    Samson Raphael

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    © All Rights Reserved
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    Proceedings of PVP2005 eae 2005 ASME Pressure Vessels and Piping Division Conference re July 17-21, 2008, Denver, Colorado USA PVP2005-71659 ACOUSTIC RESONANCE IN A PACKAGE BOILER AND ITS SOLUTION ~ A CASE STUDY FRANTISEK L. EISINGER ROBERT E. SULLIVAN, CONSULTANTS ABSTRACT ‘Strong acoustic resonance with acoustic pressures s Strouhal number reaching up to 165 dB developed in the boiler bank T = transverse tube spacing or gas of a package boiler at full load. At first, the temperature resonance developed at a lower frequency in the v flow velocity in gap between tubes ownstream portion of the tube bank and it was W = flow channel width suppressed by an acoustic baffle covering the K = coefficient to input enerey downstream section of the flow channel. After about parameter MAp ‘one year of operation, a second resonant condition © = _ solidity ratio of tube bank (volume developed, ‘Tests confirmed that again strong resonant condition developed ata higher frequency in ‘the unbaffled upstream portion of the flow channel. Computer analysis confirmed that the inal INTRODUCTION resonance occurred at the first acoustic mode of the flow channel while the follow-up resonance oveurted rAsuoui resonance ieay ceva in tana bans atthe second mode ofthe low channel expressed as exposed’ to erosallow ifthe, norte shealing a frst mode resonance in a different (upseam) _ffegueney coincides with the acoustic requencics at ratio occupied by tubes) location, | An extension of the acoustic baffle the tube bank's flow channel. I has been established the entire depth of the tube bank eliminated that the strength of the acoustic resonance is the vibration. The paper gives a description of the primarily a function of the product of the Mach problem and summarizes the theoretical and number M and the pressure drop Ap of the cross flow experimental results substantiating the findings, ts (fae through the tube bank, ie. a function of the input ‘energy parameter Map. The tube bank geometry and NOMENCLATURE, the associated acoustic damping within the tube bank © = speed of sound plays also a role as in some cases despite a resonant Ditate tube outside diameter condition, the resulting acoustic pressure levels may f frequency be small, leading t0 2 non-vibratory or a mild L tube longitudinal spacing acoustic resonance condition. M = Mach number based on gap A large body of literature is available dealing with velocity these phenomena. N= umber of tube rows in flow Please refer to papers by Weaver {1], Paidoussis [2] Sirection Blevins and Bressler [3],{4], Blevins [5] and a book P= maximum acoustic pressure, RMS by Blevins [6]. Detaled information, on acoustic 4p = pressure drop of erossflow through resonance on operating full size tubular heat tube bank exchangers and their evaluation can be found in Il Copyright © 2005 by ASME papers by Eisinger et. al. [7], ond Bisinger and Sullivan [8},[9}, {10}. The latter papers are related to the present paper in defining vibration threshotds of full size units [7.8], showing that acoustic pressure levels a resonance are typically much higher in full size units than predictions based on laboratory experiments {9}, and also that suppression of acoustic. waves can be obtained by acoustic baffles which disturb the acoustic waves but do not change their frequency U0). DESCRIPTION ‘The boiler bank with an in-line tube arrangement consists of seventy three rows of tubes arranged vertically with an outside diameter of D = 50.8 mm at T = 108mm side spacing and L = $72 mm longitudinal spacing, The tubes are located within a 1.78m wide (W = 1.78m) and 3.66 m high (H = 43,66m) flow channel. ‘The tubes contain steam on the nside and are exposed to hot gases in crossflow on the outside, There is @ temperature gradient of the ‘gases along the flow path: entering the tube bank at 712 °C and leaving at 375°C. The gas flow velocities through the tube bank change according to the temperature. The gap crossflow velocities entering ‘and leaving the tube bank are 46 m/s and 30 mis, respectively. The maximum pressure drop of the ‘gases through the tube bank, based on experimental measurements is 3,085 Pa, Figure 1 shows the ‘general arrangement of the boiler bank and Figure 2 shows the gas temperature and velocity profile. Initial Acoustic Resonance Experienced in Operation Strong acoustic resonance and vibration developed in the boiler bank at full load flow. Experimental measurements revealed that the acoustic resonance condition developed in the cooler (downstream) portion of the tube bank at a frequency of 132 Hz, Based on experimental sound measurements on the outside of the unit and the sound transmission loss through the walls evaluated ‘at SSqB, the sound pressure level on the inside reached 165 dB (ref. 2.x 10° Pa). Figure 3 shows the acoustic pressures along the flow path inside the flow channel based on the experimentally determined ‘measurements taken on the outside, It can be seen that the acoustic resonance was clearly occurring in the downstream portion of the tube bank only. Figure 4 shows the results of a finite element acoustic modal analysis of the acoustic spaces of the boiler bank and the supetheater banks located upstream. ‘The predicted first mode frequency of 138 Hz is reasonably close to the measured frequency of 132 Hz, considering the uncertainties of the temperature gradient of which it is a function. The mode shape shows that at the first mode frequency, the high acoustic pressures are located only in the downstream portion of the flow channel extending approximately over 46 tube rows. Table 1 summarizes the acoustic and flow parameters of the downstream portion of the tube bank. As indicated, the tube bank resonated at a frequency of 132 Hz with a maximum sound pressure level of 164.7 4B (3436 Pa) at an average flow velocity of 31.8 m/s with a Strouhal number of S 0.21 and a 132 Hz vortex shedding frequency. With 4 pressure drop through the tube bank of Ap = 1944 Pa and a Mach number of 0.0654, the input energy parameter is MAp = 127.1 Pa, From the relationship between acoustic pressure P and input energy parameter Map P=«MAp, ‘we obtain for the resonating condition a value of 3436/1271 = 27.0. This value is clearly representative of a vibratory condition,{9] Based on the experimental results in conjunction with the theoretical analysis, it was decided to eliminate the acoustic vibration by providing an ‘acoustic baffle atthe center of the flow channel in the affected downstream portion covering 46 tube rows. Figure 5 shows the baffle arrangement. Follow-up Acoustic Resonance Following the installation of the acoustic baffle, the unit operated successfully. After about one year of operation, the unit stated vibrating again. The delay may have been caused by contamination of the tube bank by slag deposits from oil firing, which, ‘when removed made the bank again vulnerable «0 vibration. Experimental measurements confirmed that this time the vibration occured inthe unbaffled upstream portion of the flow channel and materialized at the fall load flow at a frequency of 164 Hz, a frequency higher by 24% from the previously experienced vibration. Figure 6 shows the acoustic pressure levels in the flow channel, based on the experimental measurements. It can be seen that the maximum acoustic pressure at 159.9 dB occurred in the location in the unbafled region, at about the upstream edge of the installed baffle. Table 2 gives a summary of the flow and acoustic parameters for the upstream (27 tube rows deep) portion of the tube bank. Figure 7 shows the predicted acoustic mode shape as determined by finite element analysis based on the temperature gradient input, The predicted frequency at 162 Hz is very close to the measured fiequency of 164 Hz. The mode shape represents the second mode of the flow channel expressed asa fist mode resonance across the width with the maximam acoustic pressures located inthe upstream portion, The evidence provided by the experimental results and also by the theoretical analysis clearly indicates Copyright © 2005 by ASME thatthe acoustic resonance originated this time in the upstream (27 tube rows deep) portion of the tube bank From the Table 2 data, we can see that the resonance occurred at an average velocity of 41.5 mis with a vortex shedding frequency of 164 Hz at a Strouhal number of $= 0.2. Ata pressure drop of Ap = 1141 Pa and a Mach number of M = 0.071, the input energy parameter is MAp = 81.0 Pa. With the acoustic pressure P = 1977.1 Pa (159.9dB) the coefficient x for the input energy parameter P/Map = 1.977.1/81.0 = 24.4. This value is again representative ofthe vibratory condition [9]. ‘The obvious solution to this problem is to install an additional acoustic baffle in the upstream portion, or an extension of the previously installed baffle covering the upstream portion, Figure 8 shows the final acoustic baffle arrangement. Following the installation of the baffle, the vibration was fully eliminated. DISCUSSION We have shown that the solution to the problem described was a two stage solution. Initially there ‘were no signs of any resonance problems occurring inthe upstream portion of the flow channel neither in the boiler bank nor in the superheater bank as the ‘measured acoustic levels were very low. It was only after the vibration in the downstream section was eliminated that the vulnerability of the upstream section materialized. The acoustic pressure levels in the upstream section of the boiler bank and also in the supetheater bank have increased. However, the increase in the superheater bank was much less and its evaluated resistance to vibration much greater, confining the implementation of corrective measures to the upstream section of the boiler bank only. It is conceivable to assume that a portion of the available criving energy was absorbed by the vibration in the downstream portion. Once this vibration was eliminated, the eneray became available to drive the remaining (upstream) portion of the tube bank By providing the acoustic baffles at the center of the flow channel, the acoustic frequencies of 132 Hz or 164 Hz are not changed to any significant degree as the baffles act to only disturb and suppress the acoustic waves [10]. Based on experimental evidence, tho installed baffies will reduce the acoustic pressure levels by 32 dB [11], making the package boiler bank vibration free SUMMARY AND CONCLUSIONS Daring intial operation, strong acousti resonance developed in the boiler bank at fill load. The acoustic resonance originated in the downstream portion of the tube bank with acoustic pressures reaching 165 dB at an acoustic frequency of 132 Hz. Analysis confirmed that the acoustic waves: were representative of the first transverse acoustic mode of the flow channel and were generated by vortex shedding at resonance from the gas flowing across the tubes. The acoustic resonance was suppressed by an acoustic baffle placed at the center of the flow channel in the affected downstream section After about one year of operation with the installed acoustic baffle, a new and again strong acoustie resonance developed in the boiler bank after leaning of the boiler bank from deposits. Experimental tests and analysis confirmed that the acoustic resonance was located in the unbaéfled upstream section of the tube bank and manifested itself with acoustic pressures reaching 160 dB at a Frequency of 164 Hz. The acoustic wave developed in the transverse direction of the flow channel in the second acoustic mode of the flow channel with the ‘maximum acoustic pressures located in the tube bank upstream section. Installation of an acoustic baffle in the upstream portion of the flow channel (en extension of the previously installed baffle), climinated the vibration. In both instances, the acoustic resonance was driven by crossflow-induced vortex shedding which resonated with the transverse acoustic waves in the tube bank flow channel. It appears that the climination of the vibration in the downstream section after its first occurrence, made more eneray available to trigger and drive the vibration in the upstream section. ‘This experience leads us to the conclusion that ‘more conservative approaches are needed to be implemented in solving acoustic resonance problems. Specifically, the theoretical predictions included in the paper should have been sufficient in resolving the vibration problem after its first occurrence, regardless of the initial experimental results wiich did not indicate a problem in the upstream sections References [11 Weaver, DS., 1993, “Vortex Shedding and Acoustic Resonanee in Heat Exchanger Tube Arrays”, Technology for the ‘90s, The ASME Pressure Vessel and Piping Division, ‘The America Society of Mechanical Engineers, Chapter 6, pp. 777-810. [2] Paidoussis, M.P., 1980, “Flow-Induced Vibration in Nuclear Reactors and Heat Copyright © 2005 by ASME By (4 i (8 a Exchangers”. Practical Experiences and State of Knowledge. IUTAM-IAHR. ‘Symposium on Practical Experiences with Flow-Induced Vibration, Ed. E. Neudascher and D, Rockwell, pp. 1-81. Devlin. Springer Verlag. Blevins, R.D., and Bressler, MM. 1987, Acoustic Resonance in Heat Exchanger ‘Tube Bundles. 1. Physical Nature of the Phenomena", ASME Journal of Pressure ‘Vessel Technology 109.pp.275-281. Blevins, R.D., and Bressler, M.M., 1987, “Acoustic Resonance in Heat Exchanger Tube Bundles. Il, Prediction and ‘Suppression of Resonance”. ASME Journal of Pressure Vessel Technology 109, pp. 282- 288, Blevins, RD, 1984, “Review of Sound Induced by” Vortex Shedding from Cylinders", Foumal of Sound and Vibration, 92, pp. 455-490. Blevins, RD. 1990, “Flow-Induced Vibration “, Van Nostrand Reinhold Co., New York. Bisinger, F.L., Francis, .T., and Sullivan, RE, 1996," “Prediction "of Acoustic Vibration in Steam Generator and Heat Exchanger Tube Banks", ASME Journal of Pressure Vessel Technology, Vol. 118, pp. 221-236, Bisinger, FL, and Sullivan, RE, 1996, “Experience "with Unusual Acoustic m in Heat Exchanger and Steam Generator Tube Banks,”, Journal of Fluids and Structures, Vol. 19, pp. 99-107 Eisinger, F.L., and Sullivan, RE., 2005, “Acoustic Vibration Behavior of Full Size ‘Steam Generator and Tubular heat Exchanger Tube Banks ~ A Brief Note”, Proceedings of the ASME Conference on Flow Induced Vibration, July, Denver, Colorado Risinger, FL, and Sullivan, RE., 2003, “Suppression of Acoustic Waves in Steam Generator and Heat Exchanger Tube Banks”, ASME Journal of Pressure Vessel ‘Technology, Vol. 125, pp. 221-227. Weaver, D.S., Ziada, S., and Feenstra, P., 2002, “The Effect of Baffle Plates on Pressure Drop and Acoustic Resonance, Supplemental Report, McMaster University, Hamilton, Ontario, Canada, May 2002. Table Acoustic and Flow Paramezes af Bole Tbe Bank Downateam Section Sater eB WT TT =] Pe [ie] Pope J Pra a mp ome ie i ae Down [TE] D050 [178 [OTOH | OOS | HE aOR | aems | OT | oes | OOe | Tae | RAT] saz | ao | ae steam Ee es (1687) Table 2 ‘Acoustic and Plow Paramter of Boiler Tube Bank DT Pty t [eft] © 7s] «© ]™ ) a [Mary P [x 76 7 PIMap a 7 aay a et cB) Upscam | 168 | HOSE | TTA | OIE POOR | aS [Tae | SET | OD | OIA | UM TAT] BIO | LemT | aaa | OF Ss _Ldss9y LJ 4 Copyright © 2005 by ASME E |

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