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Vibration and Noise problems in steam generator tube bundles http://vganapathy.tripod.com/vibrn.

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Noise and Vibration Problems in Tube Bundles by


V.Ganapathy

Introduction
Tube bundles in heat
exchangers,boilers,superheaters,economizers and air heaters are
often subject to vibration and noise problems. Vibration can lead to
wear and consequent tube failures.Large gas pressure drop
across the equipment is also a side effect.Noise problems can be
a nuisance to operating personnel.This article deals with vibration
problems which occur in cross-flow situations in steam generator
components.
Whenever gas(or air) flows over a tube bundle in inline or
staggered arrangement,vorticies are formed and shed beyond the
wake of the tubes,resulting in harmonically varying forces
perpendicular to the flow direction.It is a self excited vibration and
the frequency of vibration is called vortex shedding frequency.If
the frequency of vibration of the Von-karman vortices as they are
called coincide with the natural frequency of vibration of the tubes,
resonance occurs leading to bundle vibration.
Another phenomenon that occurs with vortex shedding is acoustic
vibration,leading to noise and high gas pressure drop.Standing
waves are formed inside the duct.The acoustic pressure
fluctuations are a maximum where the fluid motion is zero;hence
the walls of the enclosure are subject to pressure pulsations and
may distort outwardly.The duct or the bundle enclosure vibrates
when the vortex shedding frequency coincides with the acoustic
frequency.Though a few simple checks are proposed below,there
are by no means complete. Experience with similar sized units,tube spacings and tube size is helpful in predicting probability
of vibration problems.

Design methods to check vibration and noise Example


The first step in the analysis of bundle vibration and noise is the estimation of A tubular air heater 11.7 ft wide,15 ft
the vortex shedding frequency fe,cycles/s.This may be obtained from Strouhl deep and 13.5 ft high(length) is used in a
number S. boiler.Carbon steel tubes of size 2x0.08
S=fe d/(12V),where d=tube OD,in and V=gas velocity,ft/s.Figure above in are used in inline fashion with a
shows typical S values for inline tube bundles per Chen. There are also transverse pitch(st) of 3.5 in and
similar charts developed by Fitzhugh and others; it may be noted that for the longitudinal pitch(sl) of 3 in.There are 40
same values of tube bundle spacings, different charts give different S tubes wide (3.5 in pitch) and 60 tubes
values,leading to different vortex shedding frequencies. Hence in the author's deep(3 in pitch).300,000 lb/h of air at an
view the results of vibration analysis is still subject to interpretation and average temperature of 219 F and
judgement calls and not like the computation of say gas velocity,where atmospheric pressure flows across the
everyone comes up with nearly the same answer! Calculations tubes.The tubes are fixed at both
apart,experience based on similar sized units in operation is a big help in ends.Tube mass per unit length=1.67
determining if noise or vibration is a concern.The author's books show the lb/ft.Check for noise and vibration
other charts for staggered arrangements developed by Fitzhugh and Chen. problems.
Natural frequency of vibration of tubes,fn Solution
For a uniform carbon steel tube supported at ends, fn,is obtained by the Let us compute fa,fe and fn. L=13.5
formula: ft,d=2,di=1.84 in,M=1.67 and C=22.37
fn=90C[(d4-di4)/M]0.5/L2 fn=90x22.37x[(24-1.844)/1.67]0.5/13.52

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Vibration and Noise problems in steam generator tube bundles http://vganapathy.tripod.com/vibrn.html

where L is the span in ft,M=mass of tube including the fluid inside,lb/ft and =18.2 c/s in mode 1. In mode 2,C=61.67
d,di are the outer and inner diameters,in.C is a constant. For clamped and fn=50.2 c/s
ends,C=22.37 ,61.67 and 120.9 in modes 1,2 and 3 respectively. Let us compute fe.S for st/d=1.75 and
Acoustic frequency ,fa. sl/d=1.5,S=0.33 from figure above.
fa=Vs/(2w/n),where w=width of bundle,ft,n= mode of vibration and Vs=sonic air density at 219F=40/(460_219)=0.059
velocity.ft/s. lb/ft3
For air and flue gases,Vs can be shown in rectangular ducts to be about Free gas area=40x93.5-2)x13.5/12=67.5
49(460+t))0.5 lb/ft2
where t= gas temperature,F. air velocity across
tubes=300,000/(67.5x3600x0.059)=21
Checks for vibration and noise
ft/s
1.Calculate fn for different modes.Compute fe at different loads. If fe and fn
Hence fe=12SV/d=12x0.33x21/2=41.6
are within 20% then vibration is likely,particularly if it is in mode 1,which has
c/s
the highest amplitude of vibration. 0.5
2.Estimate fa at different loads.Compare fa with fe. If within 20%, then Compute fa. Vs=49x(219+460) =1277
acoustic vibration and noise is likely. ft/s. width w=11.7 ft. hence
fa=1277/23.4=54.5 c/s in mode 1 and
Eliminating noise problem
109 c/s in mode 2.
Acoustic baffles are widely used to eliminate noise concerns. When a baffle
Hence it is seen that in mode 1,fa and fe
is inserted in the tube bank,reducing the width by half or a third,the acoustic
are close suggesting possible noise
frequency doubles or triples as shown in the equation above.(w is reduced
problems. fn is far apart from fe and
when the baffle is inserted).Inserting two baffles would triple the acoustic
hence tube vibration is not a concern. If
frequency.Hence the vortex shedding and acoustic frequency are kept wide
we inserted a baffle dividing the width
apart.
into nearly two equal halves,then the
Similarly if tube bundle vibration is seen,then intermediate tube supports may acoustic frequency in mode 1 is 109
be used to change the natural frequency of the tubes or the length or tube c/s,far apart from fe,eliminating the
size may be varied to minmize the concern. acoustic vibration concern.

Conclusion
Vibration calculations are often subject to controversy as the vortex shedding frequencies can be different with different
Strouhl numbers from various charts. Also it is often difficult to isolate the cause of vibration due to environmental factors.
Experience is very helpful in dealing with these issues as calculations sometimes could suggest problems when
there is none and vice versa.Sometimes the vortex shedding frequencies coincide with transverse acoustic
frequencies and yet no standing waves are formed. A damping criterion has been proposed by some engineers
based on tube spacings.There are papers which point out that the damping criterion for bare tubes is 600 and
about 15,000 for finned tube bundles. These are based on specifc studies and may have limitations when used in
broad context.Finned tube bundles have more damping effect in general and hence compared to bare tube
bundles they have fewer problems.However there could be exceptions.

Books,Software,Papers on Boilers,HRSGS,Steam plant calculations


email Ganapathy

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