88 Int. J. Nuclear Energy Science and Technology, Vol. 3, No.

1, 2007

Experimental investigation of flow-induced vibration

in PFBR steam generator sector model

M. Thirumalai*
Condition Monitoring Section (CMS)
Fast Reactor Technology Group (FRTG)
Indira Gandhi Centre for Atomic Research (IGCAR)
Kalpakkam, Tamil Nadu, India
Fax: +00 9144 27480311
E-mail: mtl@igcar.gov.in
*Corresponding author

V. Prakash, R. Srinivasan, C. Anand Babu,

R. Prabhakar and G. Vaidyanathan
Indira Gandhi Centre for Atomic Research (IGCAR)
Kalpakkam, Tamil Nadu, India
E-mail: prakash@igcar.gov.in
E-mail: rsv@igcar.gov.in
E-mail: cababu@igcar.gov.in
E-mail: rp@igcar.gov.in
E-mail: vaidya@igcar.gov.in

Abstract: The 500 MWe Prototype Fast Breeder Reactor (PFBR) is under
construction at Kalpakkam. It is a liquid metal sodium-cooled pool-type fast
reactor with all primary components located inside a sodium pool. Fission heat
is transferred to a secondary sodium system in an intermediate heat exchanger,
which is in turn transferred to water in a Steam Generator (SG). The PFBR-SG
is a vertical shell and tube-type heat exchanger with sodium in its shell side and
water in the tube side. Flow-Induced Vibration (FIV) experiments were carried
out in a water test loop on a 60-degree sector model to validate the design and
also to qualify the component for plant operation.

Keywords: prototype fast breeder reactor; PFBR; flow-induced vibrations;

FIV; vortex shedding; fluid elastic instability; steam generator; SG; modal
analysis; natural frequencies; probability density function; PDF; power
spectral density; PSD.

Reference to this paper should be made as follows: Thirumalai, M., Prakash,

V., Srinivasan, R., Anand Babu, C., Prabhakar, R. and Vaidyanathan, G.
(2007) ‘Experimental investigation of flow-induced vibration in PFBR
steam generator sector model’, Int. J. Nuclear Energy Science and Technology,
Vol. 3, No. 1, pp.88–108.

Biographical notes: M. Thirumalai is Scientific Officer of Condition

Monitoring Section at the Indira Gandhi Centre for Atomic Research,
Kalpakkam, India. He received his AMIE in Mechanical Engineering from
Institution of Engineers, India. His current research focuses on flow induced
vibration and modal analysis of fast reactor components.

Copyright © 2007 Inderscience Enterprises Ltd.

 Experimental investigation of FIV in PFBR steam generator sector model 89

V. Prakash is Head of Condition Monitoring Section at the Indira Gandhi

Centre for Atomic Research. He received his BSc in Electrical Engineering and
is a member of Indian Nuclear Society. His current research includes vibration
and noise analysis of various fast reactor components.

R. Srinivasan is Head of the Structural Mechanics Section at the Indira Gandhi

Centre for Atomic Research, Kalpakkam, India. He is MTech (Mech) from
IIT, Chennai. He specialises in FIV analysis and tube sheet analysis of
heat exchangers.

C. Anand Babu is Head of Separation Technology and Hydraulics Division at

the Indira Gandhi Centre for Atomic Research, Kalpakkam, India. He received
his PhD in Chemical Engineering. His current research includes development
of separation techniques and thermal hydraulics on fast reactor components.

R. Prabhakar is Technical Director of BHAVINI, India, a public sector

company engaged in the construction of India’s first Prototype Fast Breeder
Reactor. He was Division head of Hydraulics and Components Division at
Indira Gandhi Centre for Atomic Research.

G. Vaidyanathan is Group Director of Fast Reactor Technology Group,

IGCAR. He specialises in thermal hydraulic studies of nuclear reactor
components and fast breeder reactor steam generators.

1 Introduction

The 500 MWe Prototype Fast Breeder Reactor (PFBR) is under construction at
Kalpakkam. It is a liquid metal sodium-cooled pool-type fast reactor with all primary
components located inside a sodium pool. Fission heat is transferred to a secondary
sodium system in an intermediate heat exchanger, which is in turn transferred to water
in a Steam Generator (SG). The PFBR-SG (Figure 1) is a vertical shell and tube-type
heat exchanger with sodium in its shell side and water in the tube side. The consequences
of a steam leak into the sodium are well known with regard to both economics
and safety. One of the initiating causes for tube failure is the tube vibration caused by
sodium flow.
In the SG, the tubes see cross-flow at inlet, expansion bend and outlet locations. The
experimental studies by Pettigrew et al. (1978) and also by Gorman (1978) clearly
emphasise that the main Flow-Induced Vibration (FIV) mechanism in cross-flow regions
are periodic vortex shedding, random excitation due to turbulence and the fluid elastic
instability. The flow is parallel to the tube along the remaining part of the SG, with a
weak excitation due to turbulence. Using finite element techniques (ANSYS, 2001), the
SG tube support system is designed to provide adequate margin against FIVs and
experiments were conducted in a water test loop on a 60-degree sector model to validate
the design. These measurements were preceded by modal measurements on a three-tube
model in air (Prakash et al., 1999). Since the SG has to operate in a hostile condition
(i.e., sodium and water), it is required to prove that the support conditions are adequate
and effective against FIV.
This paper discusses the FIV measurements carried out for the sector model, the
modelling criteria, the results and the conclusion.
90 M. Thirumalai et al.

Figure 1 PFBR steam generator

TOP TUBE SHEET

TUBE SHEET

TUBE SHEET JOINT

BOTTOM TUBE SHEET

2 Modelling criteria
2.1 Comparison between PFBR-SG and 60-degree sector model
Figure 2 illustrates the sector model with the location of the intermediate support
and support details. Table 1 compares the salient features of SG and the sector model. In
the sector model, the tube diameter, inlet and outlet window dimensions and tube
supports and layout were kept identical to the PFBR-SG. SG has 23 m-long tubes. It is
not necessary to carry out measurements in full-length tubes to simulate the modal
parameters. Based on the analysis carried out, 10 m-long tubes were selected for the
model. The number of intermediate supports and their locations and a minimum tube
length of 10 m was selected in the model to simulate first few modal frequencies of the
 Experimental investigation of FIV in PFBR steam generator sector model 91

PFBR-SG. The length and the support details of the tubes at the bend region were kept
identical to the PFBR steam generator. By providing two closely spaced belts S5 and S6
(Figure 2) at an interval of 80 and 70 mm in the straight portion at either end of the bend,
the out-of-plane natural frequency has been found to be enhanced from 25 to 54 Hz,
and in addition, the tube acts as three different isolated regions (spans 1 to 4, bend and
spans 6 to 9). This analytical prediction was verified in an earlier three-tube model
experimental modal analysis (Prakash et al., 1999).

Figure 2 60-degree sector model for FIV experiments

Table 1 PFBR-SG and sector model – a comparison

Description PFBR-SG Model

Cross section Circular 60-degree sector with same radius
No. of tubes 295 45
Tube OD/ID (mm) 17.2/12.6 17.2/12.6
Tube pitch (mm) 32.2 32.2
Tube material 2.25Cr-1Mo Carbon steel
Tube length (mm) 23 000 10 000
Fluid
Shell side Sodium Water
Tube side Water Empty
No. of supports
Inlet region 15 5
Bend region No. of supports and support details are the same
Outlet region 4 4
92 M. Thirumalai et al.

2.2 Excitation and response simulation

For proper modelling, excitation mechanisms (in the cross-flow region, main excitation
mechanisms are periodic vortex shedding, fluid elastic instability and random turbulent
buffeting) and the mechanical response of the tube must be correctly simulated between
the prototype unit and the model. When water is used as the test fluid in place of sodium,
it is not possible to simulate the Reynolds number (NRe) exactly.
NRe for PFBR-SG at 673K = 4.9 × 10 + E 04 (at 2190 Cu.m./h)
NRe for 60-degree sector model (water at 323K) = 2.8 × 10 E + 04
(at 365 Cu.m./h)
NRe distortion is only by a factor of 1.75.
The Strouhal number is defined by SV = fV d0 / V
where:
SV = Strouhal number
fV = vortex shedding frequency
d0 = outer diameter of the tube
V = cross-flow velocity.
The Strouhal number is independent of the NRe over the above range (i.e., 2.8 × 10 E
+ 04 for model and 4.9 × 10 + E 04 for PFBR-SG) and is essentially a function of tube
layout (as reported by Shin and Wambganss (1977)), which is maintained in the model.
Similarly, turbulent excitation mechanism is not very sensitive to changes in the NRe
when the flow is fully turbulent, as reported by Beavers and Plunkett (1974). For
verifying against fluid elastic instability, experiments are carried out at a flow rate which
takes into account the difference in density, added mass coefficient and damping between
water and sodium. Hence nonsimulation of NRe is not a significant factor.
The natural frequency of the tube is given by:
fn = K/L2 (EI/m 0

where:
fn = natural frequency of the tube
K = constant whose value depends on end-support condition
L = length of tube between supports
E = modulus of elasticity
I = moment of inertia of the tube
m0 = virtual mass of the tube/unit length.
m0 is given by:
m0 = mass of tube + mass of fluid inside the tube + C
× mass of fluid outside the tube
where C = 1.12 (added mass coefficient for the given tube layout).
In PFBR-SG, sodium is flowing around the tubes at a temperature range of
350°C–450°C, whereas in the model, the tubes are surrounded by water at 30°C–50°C.
The inside fluid is water/steam in the case of PFBR, whereas in the model the tubes are
empty (air is inside). The ratio of modulus of elasticity to mass per unit length (E/m) in
 Experimental investigation of FIV in PFBR steam generator sector model 93

the model is closely matching that of the PFBR-SG. Hence, the natural frequency could
be simulated in the model without much variation in the span length. Natural frequency
is proportional to E/m . The material used in the SG is 2.25 chromium-1 molybdenum.
The above value E/m is computed for the model with carbon steel as material and
compared with that of PFBR-SG (Table 2). It may be noted that while the model has a
unique E/m value, in case of PFBR-SG, where the different regions are at different
temperatures, the E/m values are different. Carbon steel which has almost similar value
of E/m for the inlet, outlet and bend region was selected as the tube material. This will
also reduce the model cost.

Table 2 Comparison of E/m values for model and prototype

Location E (Pa) M total (kg/m) E/m Ratio with model

11 5
Model 2 × 10 1.122 4.22 × 10 1
SG inlet (Prototype) 1.82 × 1011 1.094 4.08 × 105 0.966
SG bend (Prototype) 1.887 × 1011 1.169 4.02 × 105 0.952
11 5
SG outlet (Prototype) 1.903 × 10 1.189 4.00 × 10 0.948

As discussed above, the Strouhal number is the same for the SG and the model and the
vortex shedding frequency is 26 Hz at the nominal flow of 2190 Cu.m./h in the SG and at
the corresponding 1/6th flow (365 Cu.m./h) in the model. But the natural frequency for
the tubes in the model is slightly higher for the tube-empty condition; hence it is
necessary to test the model at higher flow to maintain natural frequency/vortex frequency
(fn/fv) constant. The test flow for simulating vortex shedding in different regions is given
in Table 3.

Table 3 Test flow for simulating vortex shedding

Natural frequencies of dominant Test flow to simulate

modes (analytical) vortex shedding
Location SG (Hz) Sector model (Hz) (Cu.m./h)
Inlet region 27.7 28.0 369
39.0 41.0 383
46.0 47.7 378
64.4 64.5 366
Bend region 53.3 57.7 395
72.4 74.6 376
Outlet region 32.5 35.0 393
46.0 48.0 380
66.8 66.1 361

The critical velocity for simulating fluid elastic instability in the model was found to be
less than that for SG, for the first few dominant modes. Hence testing at nominal flow
condition is adequate for the fluid elastic instability criterion. In general, it is prudent to
test at 10% to 25% higher flows to account for uncertainties in the modelling criteria to
94 M. Thirumalai et al.

ensure that design-operating conditions are sufficiently separated from any thresholds of
instability. Hence most of the tests were carried out at 448 Cu.m./h (approximately 125%
of the nominal flow).

3 FIV transducers

Figure 3 shows the details of the instrumented tubes in the sector model. In the bend
region, tubes were instrumented with an aluminium shoe-mounted accelerometer and
strain gauges. There were two strain gauge-instrumented tubes at the inlet region and two
at the outlet region. Accelerometers and strain gauges were fixed at locations where
amplitudes were expected to be maximum in that span based on mode shapes, obtained
during experimental modal analysis on the SG three-tube model. Using retractable
spring-mounted accelerometers, measurements were carried out along the length of the
tubes at different locations. The location of the permanently mounted accelerometers and
strain gauges are given in Table 4. The important specifications of the strain gauges used
are given below:
• Type – Micro measurement foil strain gauge
• Gauge factor – 1.8
• Gauge resistance – 120 Ω
• Size – 6 × 3 mm grid size

Figure 3 Instrumented tube for vibration measurement in SG sector model

45 44

43 42 41 40

39 38 37 36 35

34 33 32 31 30 29 28

27 26 25 24 23 22 21 20 19

No. of tubes – 45 18 17 16 15 14 13 12

Tube OD – 17.2 mm 11 10 9 8 7

ID – 12.6mm
Length – 10000 mm
6 5 4 3

2 1

Legend
– Shoe mounted accelerometer
– Spring mounted accelerometer for
measuring tube vibration at various points
along the length of the tube
– Strain gauge
 Experimental investigation of FIV in PFBR steam generator sector model 95

Table 4 Location of permanently mounted accelerometers

Sensitive direction of vibration

Tube Transducer Span measurement
35 Accelerometer Bend region Out-of-plane and in-plane direction
12 Accelerometer Bend region Out-of-plane and in-plane direction
26 Strain gauge Bend region Out-of-plane and in-plane direction
30 Strain gauge Bend region Out-of-plane and in-plane direction
34 Strain gauge Bend region Out-of-plane and in-plane direction
22 Strain gauge Second and seventh spans Lift and drag direction
40 Strain gauge First and eighth spans Lift and drag direction

Strain gauges were bonded to the outer surface of the tubes using cyanoacrylate
compound and water-protected with silicon rubber and araldite. Salient specifications of
the accelerometers are given below:
• Model – 2222 C piezoelectric accelerometer
• Sensitivity – 1.5 pC/g
• Frequency range – 5 to 8000 Hz
Vibrations along the length of the tube at various points were measured using a
spring-mounted carriage accelerometer.

4 Description of test loop

The sector model was installed in a 300 mm-diameter water loop (Figure 4) having a
centrifugal pump rated at 500 Cu.m./h and 30 mlc. Flexible bellows were installed
between the loop pipe and the inlet and outlet of the sector model to minimise
transmission of external vibration into the model. The model was supported on a separate
structure to isolate it from pump- and loop-support structure vibration.
The flow in the test loop was controlled by means of globe valves in the discharge
line and by a pass line in the pump. The flow to the model was measured by means of an
orifice flow meter placed in the 12-inch line. The pressure drop across the orifice was
measured using a flow transmitter. The loop was filled with 3500 litres of demineralised
water for the experiment. The pH value of the water in the loop was maintained between
8.5 and 9. FIV experiments were mostly carried out at a water temperature of 318K to
323K. An expansion tank was installed to take care of the expansion of the water due to
the temperature rise during the experiment.
The water level in the tank was maintained 1.2 m above the top of the top tube sheet.
This arrangement also ensured that the model was always filled with water during testing.
96 M. Thirumalai et al.

Figure 4 SG sector model test loop

TOP TUBE SHEET

Orifice Flow
meter

Q = 500 Cu.m/h
BOTTOM H = 30 mlc
TUBE SHEET

5 Instrument schematic and measurement setup

The instruments used for FIV measurements are shown in Figure 5 for both the
accelerometer and strain gauge channels. A single-channel SRS Network analyser was
used for estimating Power Spectral Density (PSD) and a two-channel B&K analyser was
used for calculating the Probability Density Function (PDF) and for acquiring the time
signal of tube vibration.
 Experimental investigation of FIV in PFBR steam generator sector model 97

Figure 5 Instrument schematic

PC

Accelerometer/ Signal-conditioning FFT

Active filter Analyser
Strain gages amplifier

Oscilloscope

Measurements with the analyser were generally carried out at the following settings:
• Window – Hanning
• Frequency – 400 Hz
• Number of data points – 1024
• Resolution – 1 Hz
• Number of averages – 50 (0% overlap)
PSD plots obtained from the accelerometer were in acceleration units (e.g., y-axis in PSD
plots). For obtaining the displacement levels at any frequency (f), the area under the
PSD curve around that frequency was found and the resulting acceleration levels were
converted to displacement level using the following relationship:
Displacement (RMS) = Acceleration / 4π2f2
where f is the excited frequency of the tube.

Background noise level

Before commencing FIV measurements, the electronic noise level for the transducer,
amplifier and filter was measured without any vibration source being present. The results
are given in Table 5.

Table 5 Electronic background noise (RMS)

Overall Equivalent
Levels in different frequency bands (micron) (Hz)
level m/s2 displacement
Sensor (5–300 Hz) (micron) 25.3–39 30.27–47.5 39–54.7 51.7–72.2 54.7–76
Accelerometer 0.027 0.27 0.016 0.017 0.16 0.007 0.007
For strain gages Overall background strain level < 0.4 microstrain

Note: Background noise level was very low and was not expected to interfere with
FIV measurements.
98 M. Thirumalai et al.

6 FIV experiments

Tube vibration measurements were initially carried out at several flows up to a maximum
flow of 448 Cu.m./h (125% of the nominal flow) for accelerometer- and strain
gauge-instrumented tubes. Measurements were also carried out in eight other tubes at
various points along the length of the tube at 448 Cu.m./h using the spring-mounted
accelerometers. The vibration signals from the accelerometers and strain gauges after
amplification and filtering were fed to an Fast Fourier Transform (FFT) analyser for
obtaining PSD and PDF plots. For each measurement, a spectrum averaging 200 was
selected in the analyser.

7 Results and discussion

FIV measurements were carried out at several flows up to a maximum flow of

448 Cu.m./h. The three different regions (tube inlet, bend and outlet regions) responded
with different frequencies, as expected. PSD plots are shown in Figures 6, 7 and 8 for the
three different regions. Figure 9 shows the vibration time signal as the flow is increased.
Figure 10 shows the respective PDF plots of the tube vibration signal. This type of plot is
typical of a random signal, indicating that the excitation is random in nature, caused
by turbulence. Periodic excitation due to vortex shedding or fluid elastic instability
was not indicated in any of the PDF plots. Since the signal is random in nature, the peak
value was found to be approximately equal to 3.3 times the root mean squared value. The
variation in tube vibration spectra for the entire flow range tested, as shown in Figure 11,
did not reveal any resonance. Peaks in the spectra are broad and the spectra also show
closely spaced peaks. These observed frequencies matched well with the theoretically
predicted values. In experiments, it was observed that turbulent buffeting occurred at all
shell side flows and the tubes can be considered to extract energy from the turbulent field,
acting as a filter, in the frequency bands centred around the modal frequencies of the
tubes. Figure 12 gives the experimentally observed overall tube vibration level with
respect to flow rate.
When an array of closely spaced tubes vibrates in a liquid medium, fluid structure
coupling occurs and results in coupled mode with closely spaced peaks. Non-linearity in
the support can also yield this (Wambganss, 1987; Collins and Winn, 1982). When the
excitation changes over from random excitation due to turbulence to a predominantly
periodic one due to vortex shedding or instability, the PSD plots also change from
multiple-peaks spectra to a definite and sharper peak corresponding to the modal
frequency (Wambganss, 1987). Such a trend was not at all observed in flows up
to 448 Cu.m./h.
 Experimental investigation of FIV in PFBR steam generator sector model 99

Figure 6 PSD plots of vibration signal (Inlet region)

224 Cu.m./h

280 Cu.m./h

364 Cu.m./h

448 Cu.m./h

Notes: Inlet region: First span: lift-direction: tube empty

Sensor – Accelerometer: 630 mm from the top of the top tube sheet
100 M. Thirumalai et al.

Figure 7 PSD plots of vibration signal (Bend region)

224 Cu.m./h

280 Cu.m./h

364 Cu.m./h

448 Cu.m./h

Notes: Bend region: Out-of-plane direction: tube empty

Sensor – Accelerometer: 4587 mm from the bottom of the bottom tube sheet
 Experimental investigation of FIV in PFBR steam generator sector model 101

Figure 8 PSD plots of vibration signal (Outlet region)

224 Cu.m./h

280 Cu.m./h

364 Cu.m./h

448 Cu.m./h

Notes: Outlet region: Seventh span: lift direction: tube empty

Sensor – Accelerometer: 1613 mm from the bottom of the bottom tube sheet
102 M. Thirumalai et al.

Figure 9 Typical tube vibration signal

Figure 10 Vibration in PDF of tube vibration with flow

Figure 11 Variation of tube vibration spectra with flow (3D-plot)

 Experimental investigation of FIV in PFBR steam generator sector model 103

Figure 12 Overall tube vibration with flow rate

Note: Tube 28 (inlet region): second span: drag direction

7.1 Flow sweep test

The flow sweep test was carried out for accelerometers mounted in the bend, inlet and
outlet regions. The flow was gradually increased from 0 to 450 Cu.m./h. The RMS value
of the accelerometer output signal, measured with a true RMS meter, and the flow-rate
signal was obtained using a PC. Figure 13 shows the results from the flow sweep test. No
sudden increase in vibration due to resonance (vortex shedding) was observed.

Figure 13 Flow sweep test

Note: Tube 28 (inlet region): second span: lift-direction

7.2 Flow versus overall vibration amplitude

The overall level of vibration (micron-RMS) at the spans in the inlet and outlet regions,
as the function of flow rates for Tubes 20 and 28, are given in Table 6. A maximum
vibration value of 168 micron-RMS was observed in Tube 28 in the second span.
The overall level of vibration (micron-RMS, micro-strain-RMS) in the bend region
as a function of flow rates for Tubes 26, 30 and 35 are given in Table 7. The spectra
obtained from accelerometer- and strain gauge-instrumented tubes in the bend region
showed very low levels of vibration. Modal peaks were observed but their amplitudes
were insignificant.
 Flow Cu.m./h
104

Table 6
Tube Span Unit (RMS) 196 228 280 336 364 392 420 448
28 First span L; 766 mm from TTTS micron 16.2 16.9 33 65 84.3 113 130.5 166
28 First span D; 766 mm from TTTS micron 11.4 13.4 31.3 57.8 65.6 89 80.7 109
28 Second span L; 1895 mm from TTTS micron 8.5 9.6 26 54 66.4 55 78 83
28 Second span D; 1895 mm from TTTS micron 10 16 33 65 75 102 124 168
M. Thirumalai et al.

28 Seventh span L; 1613 mm from BBTS micron 6.4 6.8 9.5 15.4 19.5 21 28 37.7
28 Seventh span D; 1613 mm from BBTS micron 5.8 6.5 14.3 16.8 23.9 31.6 40 49.1
28 Eighth span L; 565 mm from BBTS micron 4.05 4.24 5.84 10.62 12.13 15.23 20.7 24.1
28 Eighth span D; 565 mm from BBTS micron 4.9 6.32 9.10 15.8 22.82 23.6 28 37.6
20 First span L; 530 mm from TTTS micron 13.7 33.73 55.07 113.9 120 134
20 First span D; 530 mm from TTTS micron 14.2 34.6 58.2 90.5 113.9 137
Overall level of tube vibration at different flows

20 Second span L; 1630 mm from TTTS micron 14.8 31.1 53.6 73.7 92.8 110
20 Second span D; 1630 mm from TTTS micron 15.8 30.2 56.5 69.4 91.1 97
20 Seventh span L; 1670 mm from BBTS micron 5.2 6.8 8.5 17.3 20.2 25
20 Seventh span D; 1670 mm from BBTS micron 4.6 7.23 9.8 18.3 25.8 34.4
20 Eighth span L; 500 mm from BBTS micron 4.14 4.34 9.32 10.45 17.6 20.7
20 Eighth span D; 500 mm from BBTS micron 4.2 4.21 7.4 9.8 10.9 18.2

Notes: D – Drag direction, L – Lift direction

TTTS – Top of top tube sheet, BBTS - Bottom of bottom tube sheet
 Experimental investigation of FIV in PFBR steam generator sector model 105

Table 7 Overall tube vibration in the bend region at different flows

Flow Cu.m./h
Tube Span Unit (RMS) 196 228 280 336 365 392 420 448
35 Bend region micron 3.56 3.65 6.24 5.50 7.70 11.40 – 17.8
(out-of-plane)
35 Bend region micron 0.68 0.66 1.19 1.00 1.25 1.40 – 2.03
(in-plane)
26 Bend region micro-strain 0.72 0.77 0.84 1.08 1.16 1.21 1.29 1.48
(out-of-plane)
26 Bend region micro-strain 0.22 0.28 0.30 0.44 0.48 0.71 0.83 0.94
(in-plane)
30 Bend region micro-strain 0.06 0.08 0.12 0.17 0.23 0.31 0.35 0.40
(out-of-plane)
30 Bend region micro-strain 0.01 0.01 0.05 0.08 0.08 0.12 0.15 0.16
(in-plane)

7.3 Vibration level of tubes in different rows

In order to find out the variation in overall tube vibrations across the tube bundles,
measurements were carried out in the spans in the inlet region of eight tubes. A
carriage-mounted accelerometer was used in these measurements. The results are
tabulated in Table 8. The maximum overall vibration level was observed in Tube 28. The
maximum vibration values of the first four rows were almost comparable, with little
variation. Vibration levels are lower in the tubes of the inner rows.

Table 8 Maximum overall vibration level (RMS) in different tubes

Tube m/s2 micron Span and direction

13 14.6 150 Second span – lift direction
15 19.4 161 Fourth span – drag direction
17 18.6 140 First span – drag direction
19 11.8 161 First span – drag direction
20 13.6 137 First span – lift direction
25 7.6 52 Second span – lift direction
28 13.4 168 Second span – drag direction
29 21.4 166 First span – drag direction

7.4 Vibration along the tube length

Using a carriage-mounted accelerometer, vibration measurements along the tube length
were carried out in eight tubes. In addition to a PDF analysis, PSD analyses were carried
out at each measurement point to find out the variation in frequency bands. Figure 14 and
Figure 15 show the variation in overall vibration amplitude in the 0–300 Hz frequency
band along the lengths of Tube 28 (inlet and outlet regions).
106 M. Thirumalai et al.

Figure 14 Vibration amplitude along the tube length (Inlet region)

(mm)

Note: Inlet region, lift direction

Figure 15 Vibration amplitude along the tube length (Outlet region)

(mm)

Note: Outlet region, lift direction

8 Conclusion

Vibration measurements were carried out up to 125% (448 Cu.m./h) of the design flow
and vibration spectra were acquired in different tubes located in different rows:
• The experimentally observed modal frequencies suggest that the three regions
vibrate independently at different modal frequencies, and that there is isolation
between them.
 Experimental investigation of FIV in PFBR steam generator sector model 107

• The modal frequencies excited were in good agreement with the analytically
predicted values.
• From the PSD, PDF and flow sweep test, it is inferred that the excitation is random
in nature and caused by turbulence.
• The maximum vibration values of the first four rows are comparable, with almost
little variation, and vibration levels are lower in the tubes of the inner rows.
• The maximum vibration value is recorded in Tube 28 in the second span (168
micron-RMS at 125% of nominal flow). For the same tube in the first span, the
vibration value is 166 micron-RMS. This shows that the cross-span effect is felt in
the second span. The resulting bending stress (3 MPa) is much less than the
endurance limit. This input would be useful for the designers to analyse and, if
possible, to reduce the number of supports.
• The vibration values in the bend regions are less and insignificant. The predominant
frequency observed is 73.2 Hz.
• As expected, the magnitude of vibration in the outlet regions is less than the inlet
region values.
In light of the above, it is concluded that the SG support system is adequate, with
sufficient margin, and the design is safe against FIV.

Nomenclature

PFBR – Prototype Fast Breeder Reactor

NRe – Reynolds number
RMS – Root Mean Square value
PDF – Probability Density Function
FFT – Fast Fourier Transform
SG – Steam Generator
Sv – Strouhal number
PSD – Power Spectral Density

References
ANSYS (2001) ANSYS Structural Analysis Guide, ANSYS Inc., Houston.
Beavers, G.S. and Plunkett, R. (1974) ‘Modelling of flow induced vibrations in heat exchangers
and nuclear reactors’, Transactions of ASME – Journal of Fluids Engineering, University of
Minnesota, USA, December.
Collins, A.E. and Winn, W.R. (1982) Measurement of LMFBR Fuel Pin Vibration in Water for
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