E L S E V I E R Chemical Engineering and Processing 34 (I995) 289-298

Chemical
Engineering
a r i a .
Processing
Flow-induced vibrations in heat exchanger tube bundles
H. Gelbe, M. Jahr, K. Schr6der
Institut f i i r Prozess- und Anlagentechnik, Teck,'nische Universitiit Berlin, StraJ3e des I7. Juni I35, 10623 Berlin, Germany
Dedicated to Prof. Dr. Dietmar Werner on the occasion of his 60th birthday
Abstract
A review is given of the most important parameters which have to be evaluated for designing tea1 heat exchangers to withstand
flow-induced vibrations. After a short description of the mechanism of excitation, stability diagrams for fluid elastic instability are
discussed. The influence of non-uniform velocities in multispan exchangers and a sectional calculation of stability relations is
explained by an example using a fluid-dynamic computer program. Some recommendations for structural data and design details
are offered in conclusion.
Synopse
Rohr e i n Rohr bf i ndel n, die quer angest r 6mt werden,
fi i hren schon bei kl ei nen Fl ui dgeschwi ndi gkei t en
st/indige Schwi ngbewegungen aus. Nach Ar t der a uf
das Ro h r wi r kenden St r6mungskr/ i ft e unt er schei det
ma n drei Gr uppen, die in Abb. 1 aufgelistet sind.
Die Tur but enzer r egung verursacht zeitlich und 6r-
tlich regellose Schwankungen, so dal3 die Ampl i t uden
relativ klein bleiben. Diese Gr unds chwi ngungen k6nnen
zu Langzeitsch~iden der Rohr e in den Uml enkbl echen
dur ch Mat er i al abt r ag ftihren, so dab bei Flfissigkeits-
und Zwei phas ens t r 6mungen in kri t i schen Appa r a t e n u.
U. der Gr enzwer t f~r die maxi mal zul~issige Ampl i t ude
die kri t i sche Geschwi ndi gkei t best i mmt .
Peri odi sche Anr egungen werden dur ch in der Str6-
mu n g auf t r et ende Dr ucks chwankungen hervorgerufen,
die a uf ei nen engen Fr equenzber ei ch beschr~inkt sind.
Die wi cht i gst e ist die yore Einzelzylinder bekannt e Wir-
bel erregung. Die St r ouhal zahl en nach G1. (1) si nd yon
der Ro h r a n o r d n u n g und von der Rohr t ei l ung ab-
h~ingig. Abbi l dung 2 zeigt bei spi el haft St r ouhal zahl en
f~r die versetzte Drei eckst ei l ung nach Weaver et al.
[9]. Diese ne hme n mi t abnehmbar er Tei l ung zu. Bei
~ = 1,25 betr/igt die St r ouhal zahl 3,6. Dami t ist die
kri t i sche Anst r 6mgeschwi ndi gkei t um den Fa kt or 18
kl ei ner als bei m Ei nzel rohr. Die ei ngebracht e ki net i sche
Energie ist zu klein, u m b e i Gasen eine bemer kbar e
Res onanzampl i t ude zn erzeugen. Auc h bei Zwei phasen-
s t r 6mungen t ri t t kei ne Wi r bel er r egung auf. Dagegen
mu g bei Fl t i ssi gkei t sst r6mungen mi t Wi rbel erregung
gerechnet werden u n d / i h n l i c h wie bei der Turbul enzer-
r egung ist zu priifen, ob der Grenzwert ffir die maxi mal
zul/issige Ampl i t ude iibe~schritten wird.
Fl ui del ast i sche Instabilit/it ent st eht aus sel bst er r egt en
Koppel schwi ngungen. Abbi l dung 3 zeigt den t ypi schen
Ampl i t udenver l auf bei zunehmender Anst r 6mgeschwi n-
di gkei t eines Bfindels. Whi rl i ng ent st eht dur ch schwing-
wegpr opor t i onal e Kr~ifte, die die Ampl i t uden am kri-
t i schen Punkt zwar steiler anst ei gen lassen, es stellt
sich aber Gl ei chgewi cht zwischen auf genommener und
dissipierter Energie ein. Bei Gal l opi ng dagegen ist der
Anst i eg abr upt , verursacht dur ch schwinggeschwin-
di gkei t spr opor t i onal e Krfifte, die der Df i mpf ung entge-
genwi rken und diese addi t i v zu Nul l oder negat i v wer-
den lassen.
Es gi bt eine Vielzahl yon Modellans~itzen fiir die
erregenden Kr~ifte, die von Chen [1] beschri eben werden.
Der filteste Ansat z, G1. (4), s t ammt yon Connor s [16].
Verwendet ma n andere Kraftans/itze, unt er Ein-
bezi ehung von geschwi ndi gkei t sabMngi gen Ant ei l en, so
erh~ilt ma n ffir Fl ui de mi t geri ngen Di cht en die gleiche
Abh/ i ngi gkei t wie in G1. (4), ftir Fl ui de mi t gr ogen
Di cht en (Flfissigkeiten) dagegen Exponent en P des
Massend~i mpfungsparamet ers, die ldeiner als 0,5 sind.
Die Prfi fung und Anpas s ung der aus den Model l -
ans~itzen gef undenen Abh/ i ngi gkei t en erfolgt i n Stabili-
t / i t sdi agrammen. Ei n solches Di a gr a mm ftir ein Bfindel
mi t versetzter Drei eckst ei l ung zeigt bei spi el haft Abb. 3.
Zur sicheren Ausl egung ist ma n gezwungen, die unt er e
290 H. Gelbe et al. ; Chemical Enghwering and Processing 34 (1995) 289-298
Begrenzung zu benut zen, die f~r gr613ere Wert e des
Massend/ i mpf ungspar amet er s dur ch die Connor s-
Gl ei chung gut beschri eben wird. I m Fltissigkeitsbereich
ist die Stabilit~.tsgrenze mi t der f/. ir Wi rbel erregung
(gestrichelt gezeichnet) i dent i sch. Ander e Aut or en, z.B.
Pet t i grew und Tayl or [15], zeigen kei nen Spr ung oder,
z.B. Tr oi dl [19], h6her e Grenzwert e.
Stabilit~itsdiagramme gest at t en die Bes t i mmung von
kri t i schen Spal t geschwi ndi gkei et en unt er der An n a h me
idealer Verh/iltnisse, das heiBt fiir homoge ne Biindel
mi t kons t a nt e m Quer schni t t (Gl ei chvert ei l ung der
Rohr e, kei ne Gassen oder Rands pal t en) sowie fiir kon-
st ant e Ans t r 6m- und Spal t geschwi ndi gkei t en in y- und
z- Ri cht ung.
I n real en W~rmet i bert ragern wird die St r 6mung
dur ch Ei nbaut en gest6rt, so dab sich ungl ei chf6rmi ge
Ro h r u ms t r 6 mu n g e n einstellen, z.B. hi nt er dem
Ei nt ri t t sst ut zen, hi nt er Prall- und Uml enkbl echen und
infolge von Biindelgassen und Rands pal t en sowie
da dur c h bedi ngt er By-pass-St r6mungen. Connor s [22]
hat seine StabilitS.tsgleichung (4) a u f ungleichm/iBige
Ums t r 6 mu n g erweitert und er Ml t GI. (7). Gl ei chung
(10) definiert die ' / i qui val ent e' kri t i sche Geschwi n-
digkeit, wie sie ei nem St abi l i t / i t sdi agramm fiir gleich-
f6rmi ge Dur c hs t r 6mung e nt nomme n werden kann.
Bei der Aus l egung realer W~irmeiibertrager ist off
eine abschni t t swei se Ber echnung pr o St r6mungsseg-
me nt zweckmfil3ig, Goyder [23]. Abbi l dung 5 verdeut -
licht dies ftir mehr f ach gestiitzte Biindel, wobei mi t
vari abl en oder mi t ' / i qui val ent en' kons t ant en
Geschwi ndi gkei t en pr o Abs chni t t ger echnet werden
kann. Ei n Vort ei l dieser Vorgehenswei se ist es u.a., dab
auch weitere yon der Rohrl fi nge abhfingige Gr61?en:
Massenbel egung, Di c ht e - - z . B. in Ko n d e n s a t o r e n - - ,
D/ i mpf ungen u n d dami t auch Stabilit~. tskonstanten [s.
G1. (11)] beri i cksi cht i gt wer den k6nnen, wobei ma n die
vari abl en Par amet er zweckmfil3ig pr o Abs chni t t n kon-
st ant anni mmt . Dur c h das differentielle Energieverhfilt-
nis AS~,,, werden die BeitrS.ge, die die ei nzel nen
Abschni t t e zur InstabilitS.t bei t ragen, gewichtet.
In real en WSxmei i bert ragern kennt ma n nur die a uf
den jeweiligen St r 6mungs quer s chni t t bezogenen Mi t t el -
werte ti' s .... und hi er mei st auch ni cht die rei nen Quer-
st romant ei l e. Moder ne Fl ui d- Dyna mi k- Pr ogr a mme
bi et en heut e die M6gl i chkei t , Geschwi ndi gkei t svert ei l -
ungen in Rohrb{i ndel n zu ber echnen und Regel n
fiir die Wahl von geei gnet en kons t ant en Geschwi ndi g-
kei t en zu ent wi ckl en, die i n der Praxis eine einfache
Di mens i oni er ung ohne Rechner ei nsat z erl auben. Bei
der Schwi ngungsber echnung mi t Fl ui d- Dynami k- Pr o-
gr a mme n mul3 ma n zur Bes t i mmung des kri t i schen
Vol umens t r oms I)'k den Vol umens t r om 12 sol ange
variieren, bis f/Jr ein kritisches Ro h r bzw. ftir ei nen
Rohr s pal t s die i n GI. (13) definierte StabilitS.tskenn-
zahl K~ = I wird. Der Z/ihler i n G1. (13) h~ingt vom
Vol umens t r om und der Geschwi ndi gkei t svert ei l ung, der
Nenner von den St r ukt ur dat en und dem K-Wert aus
dem Stabilit~.tsdiagramm ab. Rechnet ma n ab-
schnittsweise, so er Ml t ma n fth" j eden Abschni t t die
differentielle Stabilitfitskennzahl A K s , , , und Ks*. nach Gl.
(16). Dur ch die quadr at i sche Mi t t el ung domi ni er en die
Abschni t t e mi t den gr613ten Wert en yon A K s , , , .
Abbi l dung 6 zeigt berechnet e Geschwi ndi gkei t sver-
t ei l ungen fiir den gemessenen kri t i schen Vol umen-
s t r om in ei nem Versuchswfi rmet i bert rager mi t 2 Um-
l enkungen, Ur bas et al. [24]. Es wur de eine abschni t t s-
weise Ber echnung der zXK~-Werte durchgeft i hrt , ei nmal
mi t kons t a nt e n Geschwi ndi gkei t en ~V's.,, und z um an-
der en mi t ber echnet en Geschwi ndi gkei t en. Das Ergeb-
nis e nt Ml t die Tabel l e in Abb. 7. Die kri t i sche
Rohr r ei he 2 wi rd mi t K* = 0,90 bewertet, bei Gt i l t i gkei t
der Rechenvor sehr i f t Mt t e ma n 1,0 erwart et . Ei n
Gr u n d ftir die Abwei chung k6nnt e in der ri cht i gen
Bezugsgr6Be fiir die Gesehwi ndi gkei t liegen, Die bei den
Spal t geschwi ndi gkei t en ftir ein Ro h r in 2. Rei he si nd
unt erschi edl i ch und die Anst r 6mgesehwi ndi gkei t aus
dem Spal t der davor l i egenden Rei he ist gr613er. Ver-
suchsweise wur de ftir die 2, Rei he nur mi t der Spalt-
geschwi ndi gkei t der davorl i egenden Reihe, d. h. mi t
der Anst r 6mgeschwi ndi gkei t , gerechnet. Das Ergebnis
ist K ~ = 1,07, d. h. der Mi t t el wert aus den bei den
Grenzffillen zeigt eine gut e Ober ei ns t i mmung von
Model l r echnung u n d Experi ment .
Ft i r ideale Lager bedi ngungen lassen sieh Eigen-
f or men und -frequenzen yon Ei nzel rohren in Luf t
anal yt i sch berechnen. W~ihrend die ber echnet en Fre-
quenzen mi t den in B{indeln auf t r et enden r echt gut
i i berei nst i mmen, k6nnen die AmplitudenverlS. ufe wegen
ni cht bekannt er Lager df i mpf ungen und unt er-
schi edl i cher Last enver t ei l ungen in ei nzel nen Abschni t -
t en st~irker variieren. Bei Rohr en mi t unt erschi edl i chen
Stiitzl/ingen ( Fenst er r ohr e) ist in allen Abschni t t en mi t
ei nem ei nhei t l i chen We r t f , zu reehnen, Leyh [29] konn-
te zeigen, dab selbst in Versuehen mi t sehr kl ei nen
Lagerspi el en von 0,15 mm in den Sttitzblechen der erste
Sc h wi n g mo d e - - a u c h in den Abschni t t en mi t den ge-
ri ngst en St i i t zwei t en- - domi ni er t e.
Bei den D/ i mpf ungen sind drei Ant ei l e zu unt erschei -
den: Mat er i al df i mpf ung, vi skose D' ampf ung und St ruk-
t ur d/ i mpf ung. Di e St r ukt ur d/ hnpf ung liefert in real en
Appa r a t e n den gr6Bten Ant ei l und wird ver ur sacht
dur ch mechani sehe und viskose Rei bung der Rohr e in
den Bohr ungen der Sttitzbleehe sowie dur ch St6Be in
den Blechen. J ahr [32] konnt e zeigen, dab die Mat eri al -
d/ i mpf ung fiir fest eingeschweiBte Rohr e unabhfi ngi g
von der Ampl i t ude ist, dab j e doc h bei axial be-
weglichen, dur ch Gummi r i nge fixierten Lager n eine
st arke Ampl i t udenabh~i ngi gkei t auft rat . Die St r ukt ur -
dS.mpfung zeigte sich sowohl v o n d e r Lagerbrei t e und
Lager t ol er anz als auch von den Ampl i t uden abh{ingig.
Sie ni mmt aul3erdem zu, wenn die Sttitzbleehe ni cht in
H. GeIbe e t a / . / Chemical Engineering and Processing 34 (I995) 289- 298 291
den Schwingungsknoten (fiquidistante StftzstelIen)
angebracht werden.
Aus GI. (22) lassen sich die folgenden konstruktiven
Mal3nahmen entnehmen: Die Rohreinspannlfinge L hat
den sffirksten Einflul3 auf die Stabilit/itsgrenze, gefolgt
vom mittleren Rohrdurchmesser D m mit einem Expo-
nenten 1,5. Die Wanddicke s geht wie der Elastizi-
t~itsmodul E mit der Wurzel ein. Der Einflul3 der Masse
m ist f f r P -~ 0,5 vernachl/issigbar. Durch Erh6hung der
D~impfung Ai l~il3t sich Ws,k erh6hen, wobei breitere
Lager, kleinere Lagerspiele, ungleiche Stftzabstfinde
oder zus~itzliche D/impferelemente, die den Str6mungs-
querschnitt m6glichst wenig versperren sollen, helfen
k6nnen. Gassen im Bfndel sind zu vermeiden oder
durch Dichtstreifen bzw. Verdr~ingungsk6rper zu
versperren.
Bei Rohrbfndel n mit gleichen Stftzlfingen ist der
Eintrittsbereich unter dem Stutzen der kritische. Daher
ist die Gf t e der Eintrittsverteilung entscheidend f f r den
Grenzvolumenstrom. Hilfe sind Jalousie-Verteilerbleche
(keine Praltbleche!) in Verbindung mit einem
entsprechend gr61?eren freien Raum fiber dem Bfindel
oder die Anbringung gr61?erer oder mehrerer Stutzen
am Eintritt. Der Abstand zwischen Stutzenaustritt und
erstem Rohr sollte nicht kleiner als zweimal
Rohrdurchmesser sein, Jahr und Gelbe [26]. Der
Einflul? von Prallblechen wurde von Leyh [29] unter-
sucht. Als Ergebnis ist festzuhalten, dal3 Prallbleche
nicht geeignet sind, die Schwingungsanffilligkeit zu
verbessern, sondern in den meisten F~illen diese
entscheidend verschlechtern.
1. Introduction
Tube bundles subjected to a cross-flow vibrate even
at low fluid velocities. These flow-induced vibrations
are caused by time-dependent forces, which can be
determined by measuring the pressure fluctuation at the
tube surface. In order to design real heat-exchanger
tube bundles capable of withstanding critical vibrations,
it is necessary to obtain information about a number of
influencing parameters.
2. Exci t at i on mechani sm in tube bundles
Three groups of mechanism have been advanced by
Chen [1], Pa'/doussis [2], and Weaver and Fitzpatrick
[3]. They are depicted in Fig. 1.
Turbulent excitations exist even at low upstream
velocities. They are sometimes superimposed by period-
ical forces, e.g. by vortex excitation. The resulting
vibrations provide the basis for fluid elastic instability
arising from self-excited forces.
r
~ b : l c S h e d ~ c l / T L ~ b .l.e n [ B ~ fe fin g
w lfh a sm aLl. [ 'M th a b r ~ : l
F P e : ~ n c y S p e ctru m F r ~ q u a ~ S pectrum
R u ~ a s t l c
~e~g
A c o u s tic R e s o n a n c e ] I ~ 1 J 5 a t t ~ n c j k
Fig. 1. Vibration excitation mechanisms in tube bundles.
2.1. Turbulence excitation
The high flow turbulence in a tube bundle is the
cause of this form of excitation [4]. Since the fluctua-
tions are irregular in space and time, their amplitudes
are relatively small. Nevertheless they may be the origin
of long-term damage arising from material abrasion, so
that the maximum allowable amplitude may determine
the critical velocity for liquid and two-phase flow.
Semi-empirical models have been devised to calculate
these amplitudes [5,6].
2.2. Periodical excitation
Periodical pressure fluctuations limited to a narrow
frequency range, as known from single-tube vortex
excitations, are the reason for the second mechanism.
This phenomenon may excite vibration in liquid flow or
acoustic resonance in gas flow.
The Strouhal number [Eq. (1)] depends on the tube
array and on the pitch ratio of the bundle:
Sr = f w' D (1)
Woo
Undisturbed K~irmfin vortex streets can only develop
when large pitch ratios are involved; wi t h small pitch
ratios, i.e. 1.1 < ~ < 2.0, which are of greater interest
from a technical point of view, vortex formation is
impeded by neighbouring tubes. Strouhal numbers de-
pend on the position of the tube in the bundle and on
the existing flow conditions (turbulence, Reynolds num-
ber, acoustic resonance). The existence of two Strouhal
numbers has been demonstrated in square-in-line arrays
with large pitch ratios [7], and different Strouhal num-
bers were measured in the first and second row of
rotated square arrays with r > 1.31 by Weaver et al. [8].
Normally, with small pitch ratios, only the second and
third rows are endangered by vortex shedding. Beyond
the third row the periodicities are negligible compared
to broad-band turbulence. Strouhal numbers for the
normal triangular array [9] are depicted in Fig. 2. They
increase with decreasing pitch ratio.
292 H. Gelbe et al. / Chemical Engineering and Processhlg 34 (1995) 289- 298
. Q
E
z

7 . . . . , , , . , . . . . i . . . . t . , , ,
6 - - Sr = 111.73 (>1)
---Zukauskas & Katinas [15]
+ Present Results
5 + o [31 * [151 ,, [251
[ 5 1 ~ [ 1 6 1
o [ 1 0 ] o [ 2 4 ]
4
/
\ ~ , By W e a v e r et a l . [91
2 \ ' , , I S r = J ~
1 , "%.._ . . . . . u______ _ _
0 ? 1 I I I I r T [ ] ) f ) f t ) r I i [ I I I I
1 .( 1. 5 2 . 0 2. 5 3. 0
P i t c h R a t i o z
Fi g. 2. S t r o u h a l n u mb e r s f o r n o r m a l t r i a n g u l a r a r r a y s .
3. 5
Measur ement s wi t h pressure receivers or hot wires
[9,10] have conf i r med t he validity of t he upper curve
deri ved by Zukaus kas and Kat i nas [11]. Since t he
St r ouhal numbe r is 3.6 for z - - 1.25, it follows t hat t he
critical ups t r eam velocity cal cul at ed wi t h f w =./'1 is 18-
t i mes smaller t han for a single tube. Thus t he ki net i c
energy in gas flow is t oo smal l t o cause an observabl e
resonance ampl i t ude. Vor t ex exci t at i on also does not
appear in t wo- phase flow. Onl y in l i qui d flow has it
been observed. I n t hat case it has t o be checked
whet her t he t hr eshol d val ue for t he ma x i mu m ampl i -
t ude is exceeded.
2.3. Fl ui d elastic instability
A typical response f or i ncreasi ng free-st ream velocity
i n a bundl e is shown in Fig. 3. At l ow velocities,
vi brat i ons result f r om t ur bul ence and super i mposed
vort ex excitation. Addi t i onal forces, i.e. g3 and g4, occur
at t he critical velocity at whi ch fluid elastic i nst abi l i t y
commences. These forces are pr opor t i onal t o t he ampl i -
t udes x and y, t o t he respective vi br at i on velocities 2
and ):,, and t o t he respective accel erat i ons 2 a n d / ; :
m " j J + d v . f ' +Cy . y = g , ( t ) + g 3 ( y , S , , y , x ) (2)
. , <
- " Y q x
~ b ~ e n t [~.fet~qg ftuide{astic instaNily
g.O c r i f ~ t
D
F L o w V e L o c i t y
Fi g. 3. Ty p i c a l a mp l i t u d e r e s p o n s e .
m 2 + d , . . 2 + cx" x = & ( t ) + / , ' 4 ( 2 , 2 , x , y ) ( 3)
Accel er at i on forces are t aken i nt o account by addi ng
fluid mass [1], l eadi ng to a r educt i on in t he nat ur al
frequencies.
Whi r l i ng or soft self-excitation [12] occurs when pre-
vai l i ng ampl i t ude- pr opor t i onal forces act agai nst t he
stiffness. They are affected by t he mot i on of the t ube
and of nei ghbour i ng t ubes leading t o evadi ng mot i ons.
The effect of hydr odynami c coupl i ng increases wi t h
hi gher static pressure in a gas as well as in l i qui d flow
[13]. However t he influence of da mpi ng becomes domi -
na nt f or liquids [1]. At t he st art of whirling, an equi-
l i bri um exists bet ween t he absor bed and di ssi pat ed
energy.
I n cont r ast , t he ampl i t ude caused by gal l opi ng, also
called har d self-excitation [12], increases abrupt l y. Since
t he forces are pr opor t i onal to t he vi br at i on velocity,
t hey act agai nst da mpi ng and make the resul t ant forces
zero or negat i ve [2,14]. The mot i on of a t ube excited by
gal l opi ng is i ndependent of t he mot i on of nei ghbour i ng
tubes. Usual l y whi rl i ng and gal l opi ng are super i mposed
and fluid elastic vi br at i ons commenci ng wi t h whi rl i ng
change t o gal l opi ng at a cert ai n poi nt . Fr o m experi-
ence, whi rl i ng domi nat es in a gas flow t hr ough dis-
pl aced t ube bundl es and gal l opi ng of t en domi nat es in
liquid flow t hr ough in-line t ube bundl es. Thus, for a
par t i cul ar design, it is i mpor t a nt (a) t o know t he critical
velocity f or fluid elastic i nst abi l i t y and avoi d it, (b) t o
demons t r at e t he admissibility of t he ampl i t udes reached
by t ur bul ent buffet i ng (for liquid and t wo-phase flow),
(c) t o cal cul at e and check t he critical velocity and t he
mat chi ng ampl i t ude at t he st ar t of vort ex exci t at i on
(but onl y for liquids) and (d) to demons t r at e the possi-
ble i nvol vement of acoust i c resonance (but onl y for
gases).
3. Es t i ma t i n g t he cri t i cal v e l o c i t y f o r fluid e l a s t i c
i ns t abi l i t y
A numbe r of model s and theories have been pro-
posed, as descri bed by Chen [1] and Pet t i grew a nd
Tayl or [15]. The first was advanced by Connor s [16]. He
assumed an equi l i br i um bet ween t he exciting force, t he
force coefficients dependi ng on t he ampl i t udes x and y,
and t he da mpi ng force. Fr o m this he deri ved t he fol-
l owi ng stability cri t eri on for whirling:
WS.k __K. _I/@' A (4)
w~. = f . D '4 P " D-
whi ch i ncl udes t he di mensi onl ess critical velocity w~ =,
t he mass da mpi ng par amet er ( m. A) / ( p . D 2) and t he
f act or K whi ch is of t en called t he stability const ant .
Th r o u g h t he use of ot her force model s for t he
f unct i ons & and g4, i ncl udi ng t he force coefficient
H. Gelbe et al. / Chemical Engineering and Processing 34 (1995) 289-298 2 9 3
O i m e n s i o n t e s s E r i t i z a { V e t o c i t y w~
1 0 0 . . . . . . . . I . . . . . . . . i . . . . . . . . L ' '
~ & h~ A V E R ( ~ 8 1 ) o v
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* HBJCR& VII:~4T (1S81
f l 0 - i ~ , , m- n a ~ e , t a ~ m~ I / .
F o p ' r = 1 , 3 7 5 : - ,
b y T r o i d t
l
V u d e x S h e d d , - , . -
S t = 0 , ( : 8 1 , , , , . . . . I . . . . . . . . I . . . . . . . . ] i
0 , 1 1 1 0 I 0 0
M a s s D a m p i n g P a r a m e l e P m._AA
p D 2
Fig. 4. Stability map obtained by Chen [1] using the Connors equa-
tion.
depend on the vibration velocity (galloping) [17], the
same dependence as expressed in Eq. (4) for fluids
with a low density has been obtained. However for
fluids with a high density, the exponent of the mass
damping parameter in Eq. (4) becomes smaller than
0.5. For high fluid densities, correlations are often used
which make it possible to consider the damping sepa-
rately:
= K . A P ( 5 )
The stability constant K is a function of the model, the
bundle geometry, the pitch ratio and the dimensionless
velocity. A list summarizing the published values of K,
c~ and /? can be found in the papers of Chen [1] and
Andjeli6 [12].
Fitting the experimental data and verification of the
models may be achieved by means of stability :maps, in
which values for we are plotted against the mass damp-
ing parameter. Chen [1] has published maps for four
standard bundle arrays. The two staggered arrays
demonstrate a dependence on pitch [18]. As an exam-
ple, a map for a bundle with a normal triangular array
is shown in Fig. 4. The measured values are valid for
= 1.375 and were converted using the equation:
w ( O
we (r = 1.375) = (6)
2.105" (z - 0.9)
The structural data m, A and f may be del:ermined
either in air or in a non-turbulent fluid. Chen has
remarked that the validity of Eq. (6) has only been
demonstrated for gases.
From Fig. 4 it will be seen that variation in the
measurement values is quite extensive and can be ex-
plained by structural influences, unknown boundary
conditions, non-consistent use or inexact values in the
structural data, or incomplete documentation. For a
practical design, it is necessary to use the low limit
which is well described by the Connors equation for
higher mass damping parameters. Chen [1] has verified
that a discontinuity occurs in the stability curve on
changing from a compressible to an incompressible
medium. It can be seen from Fig. 4 that the lower
stability threshold in the liquid range is identical with
that for vortex excitation (dotted line). Other authors,
e.g. Pettigrew and Taylor [15], have neglected this dis-
continuity or have measured higher thresholds, e.g.
Troidl [19]. It is assumed that the extensive scattering of
measurement values in the liquid region results from
the overlapping limits for vortex excitation and fluid
elastic instability. Thus, for a safe design, the lowest
curve should be used. Turbulence excitation and fluid
elastic instability in two-phase flows have been investi-
gated by Jatzlau [20] and Chen [21].
Critical velocities determined from stability maps are
only valid for ideal conditions, i.e. homogeneous bun-
dles with a constant overall cross-section, with no side-
passages and with constant upstream and gap velocities
in any cross-section. Such conditions can only be
achieved in wind tunnels. The use of data obtained
from a stability map in the design of a real heat
exchanger will be described in the following sections.
4 . C o n s i d e r a t i o n o f a n o n - u n i f o r m v e l o c i t y d i s t r i b u t i o n
In real heat exchangers, the flow through the bundle
and around the tubes is distributed behind the inlet
nozzles, by impingement plates, banes and by-pass
gaps. This leads to axial and radial stream components
which cause a non-uniform flow field around the tubes.
Conners [22] improved his stability equation (4) for
non-uniform flow fields, but maintained the assumption
of whirling. The extended Connors equation is then:
~ L 1/ 2
j m( z ) ' @[ ( z ) dz
w* =f..~)S'kD = K' ~-7'Ai 0
/ ~z~ p ( z ) ' V s ( z ) ' @ } ( z ) dz
d
0
(7)
In this equation, ~)S,k is the critical gap velocity of the
bundle normal to the tube, @i(z) the ith vibration
mode, Ss(Z) the relative velocity function and L the
tube length.
If the tube mass and fluid density are constant, it
follows from Eq. (7) that:
~)S.k= K . A/A-~'m
f,.D ,JD2.p
with the energy ratio:
I
L ( z)
@7 ( . ) d z -
S i ~
0L@ [ (z) dz
and where the product
( 8 )
(9)
294 H. Gel be e t al. / Che mi c al Engi ne e r i ng a n d Pr o c e s s h l g 3 4 ( 1995) 2 8 9 - 2 9 8
rl =
9(z) O(z)
" / r ' - I " !
"------"ki_Im L
k
' ' 1 , l 1 1
0 l~ % t~, t~=t~, ~ l~ l~
I i 2 3 4
, _ A l l _,
Fig. 5. Sectional calculation undertaken in stages.
~?'S,k" ~ , " = ff'S,k = WS,k (10)
is t he ' equi val ent ' critical velocity ~?S,k, whi ch shoul d be
t he same as t hat obt ai ned f r om t he stability ma p f or
uni f or m flow, due t o Eq. (4).
When desi gni ng a real heat exchanger, it is recom-
mended t hat every section n be cal cul at ed separat el y
[23]. Thi s is shown i n Fig. 5 f or a mul t i s pan bundl e.
The cal cul at i on may be based on variable or on ' equiv-
al ent ' const ant velocities per section.
The advant age of this me t hod is t hat addi t i onal
par amet er s whi ch are dependent on z, e.g. mass per
uni t length, density, da mpi ng and stability const ant s,
can be consi dered. Fo r this pur pose, it is useful t o
assume me a n values wi t hi n a given sect i on n:
w * = / , , ~, K'2 (11)
: ' 7 D 2 j
where P is t he exponent of t he mass da mpi ng par ame-
t er i n t he stability equat i on. The differential energy
ratio:
~ ~ s ( Z ) ' * } ( z ) d z
ASi.,, _ l~
fo L ~ ( z )
d z
i I
@2 ( z ) d z ~ ( z) d z
~. z. - ~ J g.
= V ~ , . g = R J ~ , . ( 1 2 )
f ~ @ ~ ( z ) d z f ? O ~ ( z ) d z
defines t he pr opor t i on of i nst abi l i t y in every section.
The quant i t y qs,,, is t he ' equi val ent ' cons t ant velocity
rat i o f or sect i on n, knowl edge of whi ch is necessary f or
a safe appar at us design, at least for sections wi t h t he
l ongest span length. Nor mal l y in real heat exchangers
onl y t he me a n val ue RJs,,,, det er mi ned f r om t he vol ume
st ream di vi ded by an assumed cross-section, is known.
However, wi t h mode r n fl ui d-dynami c pr ogr ams, it is
possible t o calculate velocity fields in t ube bundles. On
t he basis of these cal cul at i ons and usi ng the equat i ons
given above, it s houl d be possible to derive rules f or
suggest i ng ' equi val ent ' cons t ant velocities whi ch ma ke
simple designs possible wi t hout t he hel p of comput er s.
Usi ng Eq. (8) or (11), it is possible to calculate t he
ma xi mum gap velocity. However, t he designer needs t o
know t he critical vol ume st ream for a given heat ex-
changer. Usi ng fl ui d-dynami c pr ogr ams, t he vol ume
st r eam has t o be vari ed unt i l for a critical gap relative
t o a critical t ube t he stability rel at i on K~ defined in Eq.
(13) becomes equal t o 1.0. It follows f r om Eqs. (4) and
(8) t hat t he pot ent i al risk of i nst abi l i t y relative t o t he
stability cons t ant K can be expressed as:
K* = __'~'s' ~ = f ( f O ( 1 3 )
Ws.k f ( O , p , A i , f , m, K)
The nume r a t or in Eq. (13) depends on t he inlet vol ume
st r eam I:" and t he velocity di st ri but i on, while t he de-
nomi na t or depends on t he st ruct ural dat a and t he K
val ue ext ract ed f r om t he stability map. The stability
t hr es hol d val ue is K* = 1. I n t hat case I~'= ~;'k and
~'s = *'s.k.
I n t he si mpl est case, i f all par amet er s are const ant
over z, Eq. (8) can be used with:
N
S , = Z AS,-.,, (14)
I 1 x 1
When cal cul at i ng section per section, one obt ai ns a
differential stability rel at i onshi p f or each section:
a x e , , , = ( 1 : )
WS,ka,
wi t h
K* = ~,~,=, AK~.,~ (16)
Because of t he square r oot value, sections wi t h t he
hi ghest AK*, values domi nat e.
The velocity di st r i but i on cal cul at ed for t he meas ur ed
critical vol ume st ream in an experi ment al heat ex-
changer wi t h t wo baffles is shown in Fig. 6 [24]. Also
s hown wi t h dot t ed lines are the assumed cons t ant ve-
locities. I n this figure, t he first three rows behi nd t he
nozzle are wi ndow t ubes and are t herefore not sup-
por t ed bet ween sections 4 and 5. Sections 1 and 2 are
not on-st ream.
Sect i onal cal cul at i ons of t he AKs*. values have been
made, based first on t he as s umpt i on of const ant veloc-
ities ~:'s,, for t he rat i o bet ween t he vol ume st r eam and
t he free cross-section of t he bundl e (in Sect i on 3 t he free
cross-sect i on bel ow t he nozzle). Secondly, cal cul at ed
H . G e l b e e t aI. / C h e m i c a l E n g i n e e r i n g a n d ProcessO*g 34 ( I 995) 2 8 9 - 2 9 8 295
g a p v e l o c i t y i n m / s
IO0
50
0
- 5 0
- 1 0 0
- 1 5 0
n = 1
.
',,,', I,,
t i
2 3 4 5
Fig. 6. Calculated gap velocities and mode shape.
. . . . . . . . . 1. r o w
. . . . 2 , r o w
- - 3 , r o w
Fig. 7. Stability relationships for a real heat exchanger.
Gap K~ for assumed K~ for calculated
constant velocities gap velocities
104-I05 0.58 1.14 1.28 0.23 0.68 0.72
205-206 0.58 1.04 1.19 0.19 0.88 0.90
305-306 0.58 0.95 1.11 0.17 1.13 1.14
with K* = x/zXK . 2 + AK~,~ +s and K = 2.48.
velocities have been used. The results are shown in Fig.
7 [25].
The constant velocity model predicts values which
are too high because:
1. The assumed velocity behind the nozzle in section 3
was too high (AK*,s = 0.53 instead of 0.23, 0.19 and
0.17, respectively); however, this has no major effect
due to the dominating influence of the ~K~, 4 + 5
values.
2. For the first three tubes in the window, the full
volume flow was assumed to be a cross-flow. In fact,
for the first row the potential risk of instability is
least because of the greater axial flow (0.68 instead
of 1.14) while the highest is found in the third row
(1.13 in comparison to 0.95).
For critical row 2, the value K* is 0.90 instead of 1.0 as
would have been expected. There is an important rea-
son for this deviation: for non-uniform flow around a
tube, the question arises which is the right dat um value
for the velocity. Thus, the two gap velocities for a tube
in a row can differ. Additionally, the upstream velocity
of a tube in the gap of the preceding row can be higher
than that in the same row. This was the case for the
second row in the sections 3, 4 + 5. For this reason, a
mean value should be established to allow the force on
the tube to be modelled exactly. Stability relations for
the second row were calculated using the gap velocity
of the row before, i.e. with the upstream velocity. The
result was K* = 1.07. Thus, it may be concluded that
the model approximately fits with the measurements.
Further validations of the extended Connors equation
have been described by Jahr and Gelbe [25, 26].
The higher values of K* (third row) relative to the
second row are surprising. This can be explained by the
fact, that the calculation model ignores by-pass streams
in the holes of the tube support plate. These lower the
velocity maximum in the third row and hence will
reduce the K* value in practice.
5. Influence of structure and design
5.1. Structure data
For the determination of critical velocities from sta-
bility diagrams, a good knowledge of the following
structure data is required: vibration frequency ~. );
damping (A;); and mass per unit length (m). Amongst
other things, they depend on the design details of the
heat exchanger, particularly on the support conditions
of the tubes and on the number and design of the
baffles.
The frequency and mass per unit length may be
calculated with a reasonable degree of exactness. How-
ever, a good estimation of the damping values is not
possible and they have to be determined after construc-
tion of the apparatus. Another problem is, that depend-
ing on the stability equation used, the structure data
mentioned above are needed for different boundary
conditions, i.e. (i) in the absence of the influence of
a fluid (vacuum), (ii) in a static fluid for (a) a single
tube (without interactions) and (b) a tube bundle (cou-
pled vibration modes), and (iii) with fluid-coupled
forces, all under realistic support conditions. Because
boundary condition (i) is the easiest to realise, Chen [1]
referred his stability diagrams to this state. State (ii)(a)
is also often used as a boundary condition (e.g. Petti-
grew and Taylor [15]), while conditions (ii)(b) and
(iii) are seldom used. Chen [27] demonstrated that
it is permissible to choose one or other of boundary
conditions (i) or (ii)(a) if this is also done for all three
parameters.
5. I. i. Frequency and vibration mode
If a very small deformation is assumed, the following
equation can be derived from the partial differential
equation for the free vibration of a homogeneous rod
[28]:
22 x/ - ~ (17)
= 27cL 2"
In this equation, t he 2i quantities are the eigenvalues
for the vibration modes @i and depend on the
boundary conditions. Tractive forces (e.g. for fixed
supports) increase the natural frequency, while pressure
forces (e.g. due to heat extension) lower it.
296 H. Gelbe et al. / Chemical Engineerhlg and Processhlg 34 (I995) 289-298
For ideal support conditions, it is possible to calcu-
late the natural modes and frequencies of single tubes
in air analytically. Although the calculated frequencies
fit very well with the measured values, the calculated
amplitude curves differ as a result of unknown support
damping and different loads in the bundle section [29].
The natural frequency for fluids of higher density de-
creases due to the additional fluid mass to be moved.
The influence of density and viscosity has been de-
scribed by Stockmeier [30].
The same value of f . has to be used in all sections for
tubes with different span length full on stream. Leyh
[29] showed that, even in experiments with a very small
baffle clearance of 0.15 mm, the first mode dominated
for sections with the shortest span length. The first
mode usually leads to the lowest critical velocity. How-
ever, if other modes are excited due to the flow field, a
higher mode can become critical. This may happen if
more than one inlet nozzle is used or if the bundle is
only partially subjected to cross-flow.
Baffle clearances are also very important. The first
mode is the only one with the lowest frequency when
the clearances are sufficiently small and the supports are
active. Whether tubes may vibrate in the mode of an
inactive support with a corresponding low frequency,
which could reach the instability area before the sup-
port becomes active with increasing velocity and ampli-
tude, needs to be demonstrated. A report about
vibrations in a condensor due to inactive supports with
clearances in the area of technical use between 0. 4-
0. 6mm has been published by Yeh and Chen [31].
Long-term damage occurred caused by increased ampli-
tudes at relatively low velocities.
5.1.2. Dampi ng
Damping may be defined by the logarithmic decre-
ment:
A = 2 n ( (18)
or by the damping ratio:
d
(19)
~ = 2,v/- ~
Three different types of damping need to be distin-
guished:
1. Mat er i al dampi ng, which occurs mainly in the sup-
ports and is not significant.
2. Vi scosi t y or f l u i d dampi ng, which cannot be neglected
for fluids with higher density and viscosity.
3. St r uct ur al dampi ng, which is the main type in real
heat exchangers. It is caused by mechanical and
viscous friction of the tubes in the baffles and also by
impact forces.
Damping generally depends on amplitude and hence on
the vibrational mode. Impact forces due to larger sup-
port clearances can cause non-linear behaviour and
hysteresis phenomena. Jahr [32] demonstrated that ma-
terial damping for welding fixed tubes does not depend
on the amplitude. In contrast, axial fi'eely supported
tubes, which are only supported by O-rings, have a high
amplitude dependence. Structural damping varies with
the width and the clearance tolerance of the support. It
increases if the baffles are not fixed in the vibration
node points (no equidistant supports, see Jendrzejczyk
[33] and Chen [1]).
Values for structural damping have been given by
Pettigrew et al. [34]. For gaseous media, A = 0.044 has
been recommended as a safe value, whereas for liquids
A = 0.062 if f > 100 Hz; for lower frequencies, higher
values are recommended. However, the damping can
also be up to five-times higher and can differ by a factor
of ca. 2 within the same bundle.
5.1.3. Ma s s pet" unit l engt h
The mass damping parameter and the frequency are
usually calculated using the mass per unit length of the
tube plus the fluid mass inside. The effect of the hydro-
dynamic mass on a single tube in infinitely expanded
media has also to be considered:
1
m,~ = -~ zrpD 2 ( 2 0 )
For air and light gases, this effect can be neglected. The
additional mass increases for tubes near to the walls
and for tubes vibrating in a bundle. Chen [1] has
defined a coefficient C,, for the effective additional mass:
c. ,
m, = --~ n p D" (21 )
and has suggested limiting values as a function of the
pitch ratio. For low amplitude values, C, usually is
assumed to be unity.
5.2. h ~ u e n c e o f design
If the moment of inertia, which depends on the
diameter D and the wall thickness s of the tube, is
introduced into Eqs. (17) and (4), an expression for the
critical velocity for fluid elastic instability can be ob-
tained:
D2 Af
WS,k "" K('c) 2~ " E 0'5' s 0'5'
L2 m O , 5 _ i, ( 2 2 )
The following design suggestions can be derived from
this equation. The span length L has .the greatest influ-
ence on the stability of the bundle and the longest span
length is the most important (window tubes). In critical
heat exchangers, window tubes must be avoided. The
influence of the mean diameter Dm of the tubes is of
next importance. Tubes with small diameters (conden-
sors) cause more vibrational problems. The wall thick-
H. Gelbe et al. / Chemical Engineering and Processing 34 (1995) 289-298 297
hess s and the modul us of elasticity E have an influence
which is proport i onal to their square root. The influence
of the mass m can be neglected for P~- 0. 5. I f the
dampi ng A,. is increased, the critical velocity can be
higher. To achieve this effect, broader supports, lower
support clearances, non-equi di st ant span lengths or ad-
di t i onal dampeners, which shoul d have no influence on
the flow field, are useful.
For nor mal t ri angul ar arrays and rot at ed square
arrays, Soper [18] discovered t hat the critical velocity
WS,k increases with increasing pitch ratio ~. Gaps within
the bundl e must be avoided or closed by using seal strips
or displacement bodies. On the one hand by-pass
streams reduce the velocity in the bundle, while on the
other hand the fluid velocity in the gaps can become so
high t hat adj acent tubes begin vibrating, especia]ily when
the flow is forced back into the bundl e at obstacles.
For tubes with equi di st ant span lengths, the inflow
area behi nd the nozzle is critical. The critical vol ume
st ream can be increased in pr opor t i on to the ratio of the
nozzle to the free bundl e cross-section. Hence the limit-
ing vol ume stream depends on how well flow is dis-
t ri but ed before ent rance into the bundle. This can be
achieved by using flow di st ri but ors behi nd the nozzle or
by using several or bigger inlet nozzles. The distance
between the nozzle outlet and the first t ube row shoul d
not be smaller t han two t ube diameters [26].
The influence of i mpi ngement plates has been investi-
gat ed by Leyh [29]. In cont rast to flow distributors,
plates are not capable of i mprovi ng the vi brat i on resis-
tance. In fact, the critical velocities were lower in most
of the cases studied. I f it is not possible to avoid plates,
their di amet er shoul d be bigger t han the di amet er of the
inlet nozzle. The distance between the i mpi ngement
plate and the shell shoul d be of a size sufficient Lo avoid
high radial velocity component s from the edge of the
plate acting on the tubes.
6. Conclusions
An overview is given of the paramet ers which affect
the vibrational excitation in a t ube bundl e heat ex-
changer as well as rules for avoi di ng their negative
influence on the critical velocity. The applicability of
stability maps with real apparat us has been inw,~stigated
in detail, as well as the influence of the velocity field and
the st ruct ural data. It has been demonst r at ed t hat a
conservative safe design is possible, but t hat some
i mpor t ant problems (e.g. dampi ng values) still require
research.
Nomenclature
c spring constant, kg s -2
Cp force coefficient, -
d
D
E
S
fw
gl ...4
I
K
K*
L
177
n
N
P
S
Si
ASi,,,
Sr
t
9
ek
W~
WS
WS,k
}VS,k
WS,k
W
X, y
2, 2
2 , 2
Z
CA
P
(
21
Ai
P
"C
~s
vel oci t y-proport i onal dampi ng, kg s - t
di amet er of tube, m
modul us of elasticity, k g m - I s -2
nat ural frequency of tubes, s-1
vortex shedding frequency, s -
external forces, kg m s -2
moment of inertia, m 4
stability constant, -
stability relation, -
span length, m
mass per uni t length, kg m - 1
number of a span section, -
number of all span sections, -
exponent of mass dampi ng paramet er, -
t ube wall thickness, m
energy fraction, -
differential energy fraction, -
St rouhal number, -
time, s
vol ume stream, m 3 s -~
critical vol ume stream, m 3 s -
free inflow velocity, m s -1
gap velocity, m s -1
critical gap velocity, m s -
maxi mum critical gap velocity, m s -~
equivalent critical gap velocity, m s-1
dimensionless critical velocity, -
amplitudes, m
vi brat i onal velocities, m s -
vi brat i onal accelerations, m s -2
coordi nat e al ong the tube, m
exponent in stability equation, -
dampi ng exponent in stability equation, -
dampi ng ratio, -
eigenvalues, -
logarithmic decrease in dampi ng, -
density, kg m - 3
pitch ratio, -
normal i zed ampl i t ude function, -
normalized velocity di st ri but i on function, -
Indices
i
k
n
S
number of mode
critical values
section of a bundl e
gap
References
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