Be. ly Unusual Acoustic Vibration of a Shell and Tube Process Heat F. L. Eisinger Faster newer Energy Corporat, into, he 08808-4000 Mem, ASME Exchanger Acoustic vibration was experienced in a shell and tube process heat exchanger over 4 large range of operating conditions. Test and analysis results confirmed that the vibration was of an unusual type, characterized by a predominantly longitudinal ‘acoustic wave rather than the usual diametral one. The typical approach of adding ‘acoustic baffles or changing the baffle arrangement leads to relatively small frequency ‘Shifts which do not assure elimination of the problem. It is proposed to solve this ‘problem by introducing sufficient acoustic damping to preven! the establishment of the longitudinal acoustic wave. Introduction ‘Acoustic waves in shell and tube heat exchangers are typically ‘excited by disturbances within the tube bundle. The excitation ‘phenomena considered to be responsible for the development Of acoustic vibration are primarily vortex shedding and tur- bulence, generated by cross-flow through the tube bundle. ‘The acoustic modes typically excited in tubular heat ex- changers are the transverse modes which are perpendicular 10 the direction of flow and the tube axes. The transverse modes in shell and tube heat exchangers are those which are related to the diameter of the shell. Barrington (1973, 1978) reported the development of diametral or inscribed square oscillating airor gas columa standing waves. Chenoweth and Kistler (1976) ‘gave design guidelines for the suppression of such waves. ‘Unusual acoustic vibration with acoustic modes developed in the flow direetion in a tubular air heater or in the tube axial direction in a steam generator tube bank were reported by Eisinger and Sullivan (1993). In this paper we present evidence of an unusual acoustic vibration in a shell and tube heat ex- ‘changer with acoustic modes developed in the shell and tube ‘axial direction. A description and analysis of this problem is presented and a solution is proposed. Description of the Heat Exchanger ‘The heat exchanger is a TEMA (Tubular Exchanger Man- ufacturer’s Association) AEU-type horizontal heat exchanger with a one-pass shellside and two-pass tubeside flow arrange- ‘ment. The U-tube bundle consists of 86 25.4-mm-(1.0-in-) dia ‘carbon steel tubes with a 2.1-mm (0.083-in.) wall thickness arranged in a triangular pattern with a pitch of 31.8 mm (1.25 in,). The baffles are single segmental with a 44-percent baffle cut, spaced 235 mm (9.25 in.) apart, except at the inlet where the first baffle is located 305 mm (12 in) from the tubesheet. ‘Conaibted by te Presse Vee 04 Piping Division and preset tthe ‘winter Annual Mesing, Anabeim, Cafornia, November £15, 1952, of Das ‘AuacasSoctar oF MceaasteasEwcoesManstrip recived by the PVP. ivslon, Ato 20,1992; revoed manuscript eesned Getber 26, 1992. At {oat Yeceal Editor: TV. Nevavana. Journal of Pressure Vessel Technology ‘The straight portion of the tube bundle is 2890 mm (113.75 in.) Jong from the tubesheet to the last support plate. The overall length, including the U-bend, is 3088 mm (121.5625 in,). The hell containing the tube bundle has an inside diameter of 477.8 mm (18.812 in.) with a wall thickness of 15.1 mm (0.594 in), The diameters of the steam inlet and the condensate ‘outlet nozzles are 203 mm (8 in.) and 51 mm (2 in.) respec tively, and are located 2654 mm (104.5 in.) apart. The shells thermally insulated on the outside by a 25.4 mm (1.0 in.) thick fberglass layer. Figure 1 shows the arrangement of the heat exchanger. ‘The shellside fluid is low-pressure superheated steam and the tubeside fluid is a process gas. The heat exchanger operates at variable steam flow conditions in order to maintain the eer) parameters forthe proses at. The dsgn operating ‘conditions are: ‘maximum steam flow: $000 kg/'n (11,000 tb/hr) steam pressure (absolute): 345 KPa (50 psi) steam temperature: 143°C (290°F) pressure drop through heat exchanger: 35 KPa (5 psi) ‘The heat exchanger operates to a large degree as a condenser asat various operating conditions different levels of condensate ‘accumulates in the shell. The condensate level changes from ‘alow of 5 percent to. high of 58 percent of the shell diameter, depending upon the process conditions. ‘Test Results Flow Parameters. Operational testing was conducted in order to better characterize the vibratory conditions, The shell- Side steam parameters, flow, pressure and temperature, and the condensate level were measured using the permanently installed instrumentation. [Nine test conditions were recorded. No vibration occurred the first three with high levels of condensate accumulated the shell, and lower steam flows. At higher steam flows (and MAY 1994, Vol. 116/1413088 (10—19") WAX OVER U-GENDS. 2955 (60K) cs SG Fig. Arrangement of hea exchanger ower condensate levels—conditions 4-9), strong acoustic vi- ‘ration was present. Table 1 gives the measured and the cor- responding computed flow parameters. ‘The data show that the condensate level in the shell is a strong function of steam flow (Fig. 2). The flow velocities were based on the flow conditions at the inlet. The cross-flow ve- locity at each test condition represents the average flow velocity ‘in the minimum gap between the tubes, determined at the edge of the baffle cut. The longitudinal flow velocity is the average flow velocity in the open flow area for steam flow in the baffle ‘cut. The cross-flow velocity in the gap between tubes (as well 4s the axial flow velocity) changes significantly asi is a fune- Nomenclature total area in baffle window ‘open flow area in baffle window speed of sound speed of sound within tube ‘bank tube outside diameter acoustic frequency in ith velocity eNok oy 142 1 Vol. 116, MAY 1994 tion of both steam flow and condensate level. Figure 3 gives the steam velocity as a function of steam flow. ‘Measured Sound Pressure Levels and Frequencies. As in- dicated before, no vibration was experienced during test con- ditions 1, and 3 at high condensate levels and correspondingly lower steam flows. A Bruel and Kjaer (B&K)-type 2230 pre- cision integrating sound level meter and a B&K-type 2515 vi- bration analyzer were used for sound measurements. All sound readings were taken on the outside of the heat exchanger with the microphone located at mid-length at a distance of 1 m from the shell surface. The frequency spectrum was relatively = acoustic pressure or sound pressure level Reynolds no. Strouhal no. = transverse tube spacing = cross-flow vel ‘axial (longitudinal) flow screen or perforated plate porosity fraction const ratio of specific heats acoustic damping parameter instability const correlation const in instability mode x, = T/D=transverse tube spacing diagram pressure loss coefficient ratio see = density Tongitudinal tube spacing x) = L/D=longitudinal tube spac“ "a = solidity ratio (volume fraction pressure ing ratio ‘occupied by tubes) ‘Transactions of the ASME‘Teble1 Measured and computed shell side flow parameters in heat exchanger T stsum [Condansate| steam | steam | Steam, | Remols | | seen ‘Test | Flow Level recsure | Temp. | "velocity | Crosstiow | _Volocty Notes oo a | ver" 279 374 we | 96 (28,800 WT a 2 |17er"| 267 374 182, 96 28,800 ‘11.7 | Vibration | | No a | rece”) 257 | cos | wee | sno | ona | 138 | veraten 2 | sie | 200 | 2a | to | 12 | 48000 | 15 | Viraton = | sr | to | 22 | ts | aso | 45000 | 238 | veraton é | as | te | a6 | 10 | 200 | 49950 | 277 | veraton > | ooo | toe | ao | es | 208 | anes | 220 | Vivaton & | so00 | oo | ae | tes | 204 | anaes | 218 | Vivaton 9 | 5545, es | me 185, | 2268 | 99,187 18.8 | Vibration indicated values are therefore approximate g a 8 srunow.rare Fig. 2 Condensate level in shel versus ste fow 6 STEAM VELOCITY, 8 ‘too 2000-3000 000 $000 6000 STEAM FLOW, kg Fig. 3 Flow velocities versus steam flow flat, with a 60-62-4B (rms) sound pressure level (SPL) in the lower frequency ranges, and an overall level of 93.7 4B (rms) in the 1 Hz2-2-KHz range. Strong acoustic vibration occurred Journal of Pressure Vessel Technology Fluctuating steam flow occurred at these conditions with the high condensate level. The 0.0 te st T T 100, 00. LAR ADR 2.00 emagoracr, ae Fig.4_ Example of acoustic pressure versus requency spectrum attest ‘oncition §| during conditions 4-9. The vibration was characterized by the presence of a strong peak at a fundamental frequency of 200 Hz, accompanied by one or more harmonics at 400, 600, 800 Hz, up to 1200 Hz. The magnitude of the higher frequency peaks changed from case to case. A typical frequency spectrum. taken at one of the Test 6 conditions is shown in Fig. 4. Table 2 gives the measured sound pressure levels atthe fundamental 200-Hz frequency and the corresponding overall sound pres- sure levels recorded in the 1-2000-Hz range. Figure 5 shows the measured sound pressure levels as a function of cross-flow velocity. It ean be seen that at the flow velocity of about 19 ai/s the acoustic vibration is suddenly initiated and increases from the nonvibratory level of 60-62 dB to a level during vibration of 77 to 91 4B, a 15 to 31-4B increase at the 200- Hz frequency. The corresponding overall level increases only by 6-9 dB, depending upon the magnitude of the higher har- ‘monics. Considering a sound transmission loss through the shell and insulation of approximately 40 dB, based on the mass law relationship (Harris, 1957), the sound pressure levels inside the heat exchanger at the fundamental frequency would be 117-131 B, levels indicative of a well-established stand wave (a standing wave in tubular heat exchangers will initiate at about 110-115 dB, depending upon the mode and acoustic damping conditions (Blevins and Bressler, 1987a and b).. MAY 1994, Vol. 116 / 143‘Table2_ Measured sound pressure levels on outside of heat exchanger versus erte-low velocity in tube int ‘iean [Sona Prue Lave a8 Sy contin | Yeleaty’ | atzn0 ne Overall Note = Frequency | (E2000) | i rm * Re euanay z 36 coe" som | "peatspecen 3 ne No Vrain = 130 Bea as Viaten A 2s 75:07 | wee 1003 | visser 5 soo} e87-685 | 61-963 | Viveton z om a Ba Veen — aa sto sts ‘Virason 3 Ze yee emerong Virsior ‘SOUND PRESSURE LEVEL, (1,48 RMS) a . 3 50) ROMAN jy 7a) 8 5 SS FLOW VELOCITY, mie Fig, 6 Measured sound pressure levels at outside of heat exchanger st m rom shell surface, Measured Structural Vibration on Heat Exchanger Shell. Simultaneously with the sound measurements, stric- tural vibration measurements (vibratory velocity and accel- eration) were also taken at four locations, A, B, C and D, at the shell surface, using accelerometers in conjunction with vibration analyzer. The results are plotted in Fig. 6. It appears ‘that the measured values are consistent with a fourth mode standing wave distributed along the shell axis. Theoretical Analysis ‘Study of Acoustic Modes. The acoustic modes within the tube bank inside the heat exchanger shell were studied by finite element methods, Diametral Mode Frequencies. The operating condition with the 178-mm (7-in.) high condensate level was evaluated. AS the steam properties change along the length of the heat ex- changer, average parameters were used: Steam temperature: 132°C (270°F) Steam pressure: (228 KPa, absolute)= (33 psig) ‘Steam density: 1.25 kg/m’ (45x 10° Ibm/in’) Ratio of specific heats: 1.4 ‘Condensate density: 920 kg/m! (33.2% 10"? Tbm/in’) ‘The speed of sound in a gas can be expressed (Kinsler, 1962) 144.1 Vol. 118, MAY 1994 Table 3. Diametral mode acoustic frequencies in heat ex- hanger shell Mode Frequency, He 7 368.0 2 ms 3 1057.1 4 nas 5 hagr 2 he = fe a 7s ® where cis the speed of sound in m/s, pis the steam pressure in kPa (absolute), p is the steam density in kg/m’, and + is the ratio of specific heats. The speed of sound within the tube ‘bank was modified by the solidity ratio (Parker, 1978; Blevins, 1986) 1 Vive where ¢” is the speed of sound within the tube bank and o is ‘the solidity ratio or the volume fraction occupied by the tubes. ‘The speeds of sound used in the analysis were: e ® (¢=505 m/s (steam outside of tube bank) = 402 m/s (steam within tube bank, 0= 0.58) ‘c= 1179 m/s (condensate within tube bank) ‘c= 1482 m/s (condensate outside of tube bank) ‘The diametral frequencies computed by finite element ‘method are given in Table 3. Figure 7 shows the first and second acoustic mode shapes, respectively. It can be seen that the experimentally measured 200 Hz dominant frequency is well below the fundamental diametral ‘mode frequency. It follows that the acoustic vibration expe- rienced was not associated with the diametral modes. Longitudinal (Axial) Acoustic Mode Frequencies In Shell Side Steam Fiow. We will study the longitudinal acoustic ‘waves using a finite element model representing the entire length of the tube bundle (from the tubesheet tothe last support baffle), with all the 12 support plates in place. The finite clement model is 457 mm (18 in.) wide, 2883 mm (113.5 in.) long, and 25.4 mm (1 in.) thick, and represents a layer of tubes and baffles taken just above the centerline of the heat ex- changer in the steam region above the condensate. The pa- rameters of the steam used in the analysis were the same as ‘those used in the diametral mode analysis. The speed of sound ‘was not adjusted by the tube bank solidity ratio as no such cffect is expected in the tube longitudinal direction. (There will ‘be an effect of the support baffles in slowing down the speed Transactions of the ASME‘SHELL TUBESHEET LAST SUPPORT PLATE a ratory acceleration ax10 Velocity, m/s Measurement locations along shell o — Theoretical acoustic pressure wave in heat exchanger shell ration, m/s o > Accel Fig. 6 Measured structural vibration at shell surface at four locations along cell ale Te fourth mode longitudinal couetis wave {3 Superimposed. MODE 1 Fig. 7 Diamotratscoust ‘of sound, This has not be included, however, for a lack of quantitative data.) ‘Table 4 gives the computed acoustic frequencies for the first 5 longitudinal modes. ‘The finite element mode! in Fig. 8 shows the longitudinal mode acoustic pressures schematically. ‘From this analysis, itis apparent that the calculated fourth mode frequency of 220.55 Hz is the frequency representing the acoustic vibration experienced. Its expected that the effect of baffles, which was not fully accounted for in the analysi ‘would reduce the acoustic frequency from 220 Hz to the meas- ‘ured 200 Hz value. Journal of Pressure Vessel Technology MODE 2 le pressure modes ‘Table 4 Longitudinal mode acoustic frequencies in heat ex- ‘changer tube bundle (original baffle cut at 44 percen ‘Mode Frequency, He 7 35.45 2 110-33 5 165.95 4 2055 5 z It is interesting to note thar the acoustic wave travels along the shel ans relatively unimpeded by the presence of the ba MAY 1994, Vol. 116 1145Table S Longitudinal acoustic frequencies in heat exchanger {tube bundle with reduced (baffle cut at 21 percent) ‘Mode Frequency, Hz 43.08 5625 109556 1290 216.10 ‘Table 6 Effect of added acoustic baffles on longitudinal acoustic frequencies in heat exchanger tube bundle Mode Frequency, He “0.9 10120 13234 20337 2asor ‘Study of Acoustic Modes in Tube Bundle With Changes in Baffle Arrangement. We will analyze the effect of changes in baffle arrangement on acoustic frequencies to see if such changes could lead to a solution of the vibration problem. Baffles With Reduced Baffle Cut. The effect of a reduced baffle cut on acoustic frequencies was studied using the same steam parameters of density and speed of sound as before. The baffle cut was severely reduced from the original 44 percent with a baffle overlap of $4 mm (2.125 in,) to a cut of 21 percent, leading to an increased overlap of 329 mm (9 in). ‘The computed acoustic frequencies are given in Table 3. Asexpected, the increased impedance due to increased baffle ‘overlap reduces the natural frequencies (a reduction of about 22 percent was achieved); but this by itself cannot give assur- ‘ances of eliminating the vibration problem as acoustic vibration could occur at the lower frequencies also. Original Baffle Arrangement With Added Acoustic Baffles. Theeffect of added acoustic baffles placed between the existing bates (Fig. 9) was also studied. The results are given in Table 6 It can be seen that the added acoustic baffles also introduce 1 reduction of frequencies (an 8 percent reduction relative to the original configuration has been achieved). From the two cases studied, we can conclude that the fre- ‘quency changes obtained by the rearrangement of baffles are considered insufficient to ensure elimination of the vibration problem. Study of Effect of Acoustic Damping. Since a solution to the acoustic vibration cannot be reliably predicted when based ‘on frequency changes due to bafile alterations, we will now examine the effect of added acoustic damping in order to increase the vibration resistance of the heat exchanger, The damping must affect primarily the longitudinal acoustic wave. ‘The most natural locations for adding impedance are the areas of the baffle cuts, where the acoustic particle velocities in the 4th mode of concern are the highest. We will examine the effect of screens of finite porosity placed in the areas of the baffle cuts. Both the effect of the screens on increasing the vibration resistance and on pressure drop through the heat ‘exchanger will be examined. Effect of Acoustic Damping on Resistance to Acoustic Vibration. As the basis for the evaluation of the damping effect, we will utilize some of the recently developed relation= ships based on a review of acoustic vibration in steam generator tube banks (Eisinger et al., 1992) We will briefly describe this newly developed relationship {as follows: the Chen (1968) and the Chen and Young (1974) acoustic vibration criterion is given by 146 | Vol. 116, MAY 1994 sere (ne) BIFRE #6800 a‘ a] id Gy DN NT ses WAYAENSES 7 seco Fig. 8. Finite eloment model with superimposed longitudinal acoustic ‘modes (original design) sone accuse romana. sxmie BRR Ge) Peed. worn BE AT USN Fig. 9 Finite element mode! with added acoustic bates Re iat B(-)5 ® where Re is the Reynolds number, S is the Strouhal number, ‘and x; and x; are the transverse and the longitudinal tube spacing ratios, respectively. ‘Equation (3) can also be expressed as ¥ vate o where o will be called the Chen damping parameter. It can be shown that the Chen and Young acoustic vibration criterion for steam ‘generator tube banks is well represented by a Re versus 5 Stability diagram with a stability line at ¥= 1300 separating all the vibratory from the nonvibratory cases (Eisinger etal, 1992). ‘A similar stability diagram correlating acoustic pressures and the corresponding acoustic particle velocities with the Chen damping parameter can also be obtained. Figure 10 shows such ‘adiagram separating the vibratory from the nonvibratory cass. Here the acoustic pressures for the vibratory cases were based ‘on experimental measurements and for the nonvibratory cases Were set at 110 4B, a value representing an approximate upper limit for the nonvibratory case. The stability line separating all the vibratory from the non- vibratory cases can be expressed by the relationship Transactions of the ASMEpee teal al ae ee ee a Gorwwmmen HES [LE ey |e! z fp SE fone (eu onMP ING PARAREETER, Bast? Fa, 10_Acousle vation stailty agra for seam generator tbe ‘banks (Eisinger et al., 1992) ‘y dos 1g Caer] ace rea teat wrens Sa0H i Ls [Prisincaig tae @ ro oauag esos gi. 2s ‘nso oon Ste ecwae rom & 138 Kove 2 Sond 90 on nied Coe oo Beamer | Ecee | oes « = 0.70) tios/ 2 3 4 6 678910 ~ [ACOUSTIC DAMPING PARAMETER, @ = Kat Fig. 11. Acoustic vibration stability dlagram for present heat exchanger inal and moditied den w) a ( E o Idee) where vp/fiD isthe dimensionless acoustic particle velocity, vp is the acoustic particle velocity, fis the acoustic frequency in the ith mode, Dis the tube diameter, Pis the acoustic pressure, ‘pecisthe characteristicimpedance ofthe fluid, isan instability Constant, and dis the damping parameter. The numerical values of { for steam generator tube banks is 1.35%10~?, which ‘corresponds to an acoustic pressure of 112.6 dB (Eisinger et al., 1992). From the diagram in Fig. 10t can be seen that the damping effect is significant. With high damping the onset of vibration is significantly delayed, or a further increase in acoustic pres- sure is required to initiate vibration. Acoustic Vibration Diagram for Present Heat Exchan- ger. Asthestat fam represents the acoustic pressures inside the tube bank, we will convert the acoustic sound pres- Journal of Pressure Vessel Technology 2 PRESSURE, H E i ; SCREEN POROSITY, a Fig.12_ increase in acoustic vibration threshold asa function of screen porosity o7 os ‘sure levels measured on the outside of the heat exchanger to values on the inside by adding the previously described 40-4B ‘ansmission loss through the walls and casing to the measured values. From the test data we thus have: For the cases with NO VIBRATION: a maximum of 62+40 =102 dB For the cases with VIBRATION: a minimum of 76.9+40 16.9 dB Figure 11 shows the stability diagram for the present heat exchanger with all the test values, (with 40 €B added) nonvi- brating and vibrating, superimposed. For the minimum bratory acoustic pressure of 116.9 dB, we find the corresponding damping parameter of 5= 1.645 (Fig. 11). The ‘Chen damping parameter (Eq. (5)) can be expressed also by @ where © is the porosity (ratio of open area to total area) of a screen of parallel tubes or bars, and. 10 Numerical Results. The average porosity of the present hheat exchanger arrangement in the baffle cut area is ay where Ay™=0,0585 m? (91 in’) is the average open flow area in the axial direction, and A = 0.0789 m* (123 in’) is the area of the baffle cut. For a=0.74 and 6= 1.645, .=0.9 in Fig. 11 Figure 12 gives the increase in the acoustic pressure threshold (based on Fig. 11) as 2 function of screen porosity. It can be seen that a significant shift in vibration initiation can be achieved with the introduction of damping. With a safety fac- tor of 2 we would need an increase of the acoustic vibration threshold by 2x14.9 4B. (The 14.9 dB characterized the in- crease from the nonvibratory to the vibratory condition in the original heat exchanger.) A sereen porosity of = 0.3 can pro- vide this increase (Table 7). MAY 1994, Vol. 116 / 147Table? Pradicted increase of acoustic prescure threshold versus soreen porosity Sawen | Damping | Troshoid of SPL for | Poroaty | Niorton ination Notes a SPB (EMS) | an “3 — = 169 [es a7 08 256 a5 ra 259 ji Roconmendad 030 1000 305 Rasermendeg [aaa Ti as oz 170. 382 rd ait aoa Tables Predicted maximum sdded pressure drop through hest exchanger with acoustic screens (maximum ‘pram esd 0.859 KPa 0082 po) ‘Screen [Pressure Drop pet 1 Soren] Total Pressure Drop (11 Screen) Porosity Paps Kapa News O74 = = 086 one aoe 050 0.40058 4.40638 t 040 28070.117 as7i.257 038 1.390702 16202 fl 7 econmended 020 17910251 [isaa7e] oes o25_|_ asa 288 023 3 017 6: Added Pressure Drop Through Heat Exchanger as a Func- tion of Screen Porosity. We will consider screens of parallel wires or rods inserted into the tube bundle, or equivalent po- rous plates inserted in windows between the tube bundle and shell at the existing baffle cuts, ‘The pressure drop 4p through a screen is given by Ap=K 12 95 03 ag where K is a pressure loss coefficient, 2s is the mass flow density, and u, is the approach flow axial velocity. ‘The values of the dynamic head of 1/2 p, v3 were computed for the range of operating conditions. The maximum value ‘occurred at condition 6 (Table 1) 1/2 po v=0.359 KPa (0.052 where vg=27.7 m/s (90.7 ft/sec) 200.94 kg/m (34% 10°$ Ib/in’) ‘The pressure loss coefficient for a sereen of parallel rods is siven by Blevins, 1984) ay 0-2) where 0.5400. ‘Table 8 gives the maximum added pressure losses through fone screen and through the total heat exchanger (LI screens), assuming a constant dynamic pressure head for each screen along the heat exchanger. In order to achieve the 2X 14.9 =29.8-4B minimum increase inthe threshold acoustic pressure, a screen porosity of a=0.3 ‘would be required (Table 7). This would increase the pressure drop through the heat exchanger (for 11 installed screens) by 19.0 KPa (2.76 psi) (Table 8), Fig. 13. x ay Discussion and Summary ‘The operational characteristics of this heat exchanger differs to a large degree from other heat exchangers of the same type. 148 / Vol. 116, MAY 1994 ‘The analysis shows that condensate level in the shell sa strong function of steam flow. A relatively small increase in steam flow results in a rapid reduction of water level. A change in steam flow and corresponding change in the condensate level leads to a large change in cross-flow and longitudinal steam flow velocity through the tube bundle. The largest rate of change in this velocity occurs when the condensate level falls just below 50 percent of the shell diameter. At this condition the steam velocities through the cube bundle increase rapidly and reach a maximum at about the 37-40-percent condensate level. The maximum velocities are 30 m/s (98.5 ft/sec) in cross- flow and27.7 m/s (90.7 ft/sec) in axial flow with corresponding Reynolds numbers of 45,00048,000 in cross-flow, During the rapid rise in flow velocity, at about 19 m/s (62.3, fi/sec) and a condensate level of 42 percent, acoustic vibration commenced. The vibration was characterized by a fourth mode longitudinal standing wave extending from the tubesheet 10 the last support plate at the U-bend, vibrating at a frequency of 200 Hz, The wave established itsef virtually unhindered by the presence of baffles. The onset of vibration was character- ‘zed by a sudden increase in acoustic pressure (by 15 dB). Once initiated ata steam flow of about 3200 kg/h (7000 Ib/fir) the ‘acoustic wave persisted over a large flow range of up to the tested condition of $500 kg/h (12,200 lb/hr). The strength of the acoustic vibration remained the same or increased slightly within this range. ‘Two different approaches for the elimination of the acoustic vibration were studied. At first, the effects of baffle rear- rangement and baffle addition were examined. This procedure led to a relatively small reduction in acoustic frequencies, and thus did not appear to offer a reliable solution. The second approach, providing a significant increasein acoustic damping, is expected to eliminate the vibratir ‘The increase in damping must be high enough, however, 10 raise the critical acoustic pressures above vibration initiation, ‘Table 7 shows that the screens placed in the baffle windows ‘with a porosity « of 0.30 will provide a 30.6-dB margin against ‘Transactions of the ASMEsod \ | | 2 olga |. asia ADDED FLOW PRESSURE DROP, as, KPO 00 01 02 03 os 05 08 O07 08 SCREEN POROSITY, a Fa ee 00 1s i nme 0) ae ea Fig. 14 Added helical spacor grids in tube bundle and perforated sup. at plates in bale windows, the onset of vibration. (This is more than twice the increase of 14.9 dB at vibration initiation in the original configuration.) A pressure drop through the heat exchanger of a maximum of 19 KPa (2.76 psi) is predicted with the screens located in the windows next to each baffle plate. ‘The excitation mechanism for the unusual acoustic vibration is not fully understood at this time. If one postulated a vortex excited system from cross-flow, an acoustic Stroubal number S,=fD/v=0.267 can be calculated, closely agreeing with the values of Chen (1968). However, this coincidence by itself does, ‘not prove that the excitation was indeed that of vortex shed- ding. A more plausible explanation may be that the vibration experienced falls into the category of coupling phenomena demonstrated to exist in enclosures with turbulent flow. (See literature review by Eisinger and Sullivan, 1993). Based on this theory, the underlying cause of this vibration would be the presence of turbulence in conjunction with vortex shedding— 2 condition always present inside a tube bank. The superim- Journal of Pressure Vessel Technology posed acoustic waves of many different frequencies and am- plitudes, also always present, would interact and couple with the turbulent flow field and at proper conditions initiate the acoustic vibrations. Within this context, it appears, the mech- anism which caused the unusual vibration in this heat ex- changer as one of a fluid-acoustc instability. Recommendations ‘The screens in the baffle cut areas can be provided in the existing heat exchanger by helical spacers Eisinger, 1981, 1990) inserted in the tube bank area. Perforated baffle plates can be used in the untubed windows. For elimination of the vibration, eleven such screens, placed in the baffle cut windows at each baffe, shoud be provided, Figure 1¢ shows the arrangement of the helical spacer grids in the tube bank at the bafiles, gonjunetion with perforated baffes inthe orignal baie vio Acknowledgment ‘The author would like to thank J.T. Francis and R. B. Sullivan for their help in the preparation of this paper. ‘The author is indebted to his colleague M. D. Bernstein who read the manuscript and offered many valuable suggestions. perience With Acoustic Vibrations in Tubular Exchange." Chemical Engnerng Progres, Vol. 63, NO, pp. 2-68. ‘Buringion EA. 1978, "CurvExchanges Acoust Vibration,” Hydrocarbon Processing, Jl, 193-198. Bienrs RD, 1988, Applied Pid Dynamics Handbook, Van Nostrand Reimold Company, New York, N'Y. Blvts, RD 1586 “Acouite Moses of Heat Exchanger Tobe Bundles," Joural of Sound and Vibration, Val. 18, No.1, 9p 19-3, ‘Bless, R. Dy and Breer, M, M1 Exchange’ Tobe Bundes—Par Physical Nature the Phesomeson,” ASME Jouna o Prasone Vases Teceneroey, VoL 103, p. 775-281 ‘Blevins, RD. and Bester, Me M., 1987, “Acoustic Resontce la Hest "Fion-Inducrd Vibration an Nowe in Tube Bank Hest ‘Eucanger Die to on Karman Steet,” ASME Journal of Engineering for Indus, WO. 90, 9p. 134186. ‘Che, YN sd Young, W. C. 1874, The Orbal Movement and the Damping ofthe Fides Vibration of Tube Banks De to Vertex Formation, Pat 3-Damping Capaliy of Tue Bank Against Vorer ached Sone Ve bration in he lid Colum,” ASME Journal of Ensinering for Indus, Vl pp 1072-108, ‘Chenoweth, JN, and Kit, RS, 1996, “Tube Vibrations io Shean ‘Tube Heat Exchange" Teenial Report, Heat Transfer Research Ist. lege, FL 98, “Rewoitin Tube Support Plate and Acoustic De tuning Eafe in Tubular Heat Exchangers,” Second Synpociu oo Sl and ‘Tbe Heat Exchanger, Sal and Tube Het Exchangers, Aenean Sout for Mats, Metals Park, OH, p. 373-37 Eisnger, FL 1980, “Bmiang Vibration Problems io Tabular Heat ‘ehanse,” ASME PVP Vol 198, How-Mndued Vibration ess SS Chon fa, Book No. HOOGOE, The American Society of Mecha! Engines, 9p Saloe Eisnpe, FL. Solan, RE. and Franc J.T. 1992, “A Review of Acoust Vibration Criteria Compared to Ine ie Expeince With Stes Gen ‘aor f-Lie Tube Banks," ASME PVP-Vol. 26, 9p. 61-95. ‘inger, F- Land Sulivan, RE 1993, “Unusel Acoutic Vibration a ‘Hes Exchanger and Star Genertor Tube Banks Poss Caused by Pid ‘Acouse Labi” ASME Journal of Eninering for Gat Turbines end Power Vo 115, pp. 411-47. "Hans, CM. B57, Hanabook of Noise Control, MeGr-Hl Book Com. “asl, LE 1982, Fundamentals of Accuses, Second Eon, Joba Wiley and Sons nes New York, NY ‘Parker Ry 199, “Acouis Resonance in Passages Contining Banks of Het Exchanger Tubes," Jourel of Sound and Vibretion, Vol. 37, NO... 25-26 MAY 1994, Vol. 116 149