MUSTEK - IAEA

TECHNICAL MEMORANDUM

MUSTEKANL-CT-8O-3

DOE/ANL/HTRI HEAT EXCHANGER TUBEVIBRATION DATA BANK

by

H. Halle, J. M. Chenoweth, and M. W. Waabsganss

Components Technology Division

February 1980

C'STiSlBUTifsrJ Or THIS SSG'SMEBT !3 UNLiMtTE3

TECHNICAL MEMORANDUM ANL-CT-80-3Engineering andEquipment (UC-38)

DOE/ANL/HTRI HEAT EXCHANGER TUBEVIBRATION DATA BANK

by

H. Halle, J. M. Chenoweth, and M. W. Wambsganss

Components Technology Division

UofC-AUA-USDOE

February 1980

<- ot ths United Slates Government of d"v agencv

Assistant Technical Director, Heat Transfer Research, Inc., Alhambra, CA

.... ••"-JV^TI;: [i-nniTEB

TABLE OF. CONTENTS

Page

ABSTRACT 1

I. INTRODUCTION 1

II. BACKGROUND 3

III. OBJECTIVES 5

IV. ASSESSMENT OF DIFFICULTIES 5

V. DATA FORM 6

VI. SOLICITATION 7

VII. INITIAL CASE HISTORIES 8

VIII. DISCUSSION 8

APPENDIX 1: HTRI Solicitation Letter for Tube Vibration Case Histories 1-1and DOE/ANL/HTRI Heat Exchanger Tube Vibration Data Form

APPENDIX 2: Case Histories 101-115 of the DOE/ANL/HTRI Heat 2-1Exchanger Tube Vibration Data Bank

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA BANK

by

H. Halle, J. M. Chenoweth, and M. W. Wambsganss

ABSTRACT

Development of a new heat exchanger tube vibration data bank at

Argonne National Laboratory is described. The objective is to accumulate

comprehensive case histories on heat exchangers that have experienced

tube-vibration problems and units that have been trouble-free, and render

this information available for evaluation, improvement, and development

of vibration-prediction methods and design guidelines. Discussions

include difficulties in generating a data bank, data form development,

and solicitation efforts. Also included are 15 case histories upon

which the data bank will be built. As new case histories are received,

they will be asseabled and published as addenda to this report.

I. INTRODUCTION

Flow-induced vibration has become a vital factor in the design of heat

exchangers along with the more traditional thermal, hydraulic, and mechanical

considerations. There have been many cases of shell-and-tube heat exchangers

experiencing vibration problems, often leading to tube failures, and, in some

cases, costly plant shutdowns. These vibration problems have motivated theore-

tical and experimental studies which have resulted in the development of pre-

diction methods and design guidelines to avoid detrimental cube vibration.

However, most of these studies involved single tubes or tube banks

subjected to idealized uniform crossflow or parallel flow conditions.

Although these conditions can occur locally, they are not

typical of the changing flow patterns throughout an actual shell-and-tube

exchanger: Flow passages, and thus flow conditions, are much more complex

than simulated by either mathematical models or experimental equivalents.

Consequently, extrapolation of these methods for predicting flow-induced

vibration problems to heat exchanger tube bundles has been seriously chal-

lenged. Available prediction methods provide useful guidance but are considered

unreliable to the extent that their application to heat exchanger design

evaluation is uncertain thus requiring the use of large factors of safety.

To examine the ability of these methods to correctly predict the absence

or presence of flow-induced tube vibrations, field data must be collected

from case histories of individual heat exchangers and stored in a manner that

can be input into these methods.

Efforts in support of such a data bank are being carried out at Argonne

National Laboratory (ANL), and funded by the U.S. Department of Energy, Office

of Fossil Energy, Division of Fossil Fuel Utilization. The activity is also

a part of a U.S. contribution to an International Energy Agency (IEA) program

of Research and Development on Heat Transfer and Heat Exchangers.

Solicitation and collection of case histories for the data bank has been

assigned by ANL to Heat Transfer Research, Inc. (HTRI), a nonprofit cooperative

of heat transfer equipment manufacturers, engineering contractors, and

processing companies to promote application-oriented research in heat transfer.

ANL is working with HTRI to take advantage of their experience with data

banks, their established contacts with manufacturers and users throughout the

world, and to ensure anonymity of contributors to the bank.

This report describes the DOE/ANL/HTRI Heat Exchanger Tube Vibration Data

Bank, including background information, objectives, assessment of difficulties in-

volved, data form development, solicitation efforts, and, as an appendix, fifteen

case histories of heat exchanger tube vibration. These histories were purchased

I

from HTRI with program funds and represent cases in which acoustic vibration,

damaging tube vibration, and no vibration were present. They constitute the

initial entries and the base upon which the new data bank will be built. As

additional case histories are received, the data will be collated and published

annually as addenda to this report.

II. BACKGROUND

The need for a bank of field data for shell-and-tube heat exchangers that

have experienced flow-induced tube vibration problems was recognized by the

Tubular Exchanger Manufacturers Association (TEMA) in 1969. Data collected

from its members represented observations of gross effects that were considered

significant parameters concerning tube vibrations. These proprietary data were

made available to HTRI in 1971. Since thet time, a new understanding of vibration

phenomena has shown that the data are inadequate to evaluate critically current

prediction methods.

In 1972, HTRI started collecting case histories for a heat exchanger tube

vibration data bank. A form was designed that requested more data than found

in the TEMA Data Bank. More specifically, case histories also were requested

for heat exchangers which had not experienced vibration problems.

The data obtained ranged from very complete to sparse. In some instances,

data gaps could be filled either by contacting the organization submitting the

case, by making back-calculations, or by using "good engineering judgment."

Although the HTRI data bank is proprietary to HTRI members, gross comparisons

of predictions by known methods with field observations have been published.

Of the more than 60 cases submitted, only 25 were sufficiently documented to

J. M. Chenoweth, "Flow-Induced Tube Vibrations in Shell and Tube HeatExchangers," ERDA Report SAN/1273-1 (February 1977).

be included in the data bank. However, only six of these cases deal with liquid

shell side flow. Additionally, the data are heavily biased toward cases for

which vibration problems have been experienced; there is a lack of cases for

which no vibration problems occurred.

In England, Heat Transfer and Fluid Flow Service (HTFS) also has collected,

analyzed, and prepared a report on tube-vibration data. However, the report

is proprietary to HTFS members.

In 1976, HTRI conducted a study on flow-induced tube vibration in shell-

and-tube heat exchangers for the Division of Conservation Research and Technology

of the Energy Research and Development Administration (ERDA). This study included

a Heat Exchanger Tube Vibration Workshop to identify the most promising areas of

needed research in flow-induced vibration in industrial shell-and-tube heat

exchangers. An international panel of 14 vibration experts, representing on-

going research, was invited to present their evaluation of the current state-

of-the-art, and to participate with other attendees in discussions and formu-

lation of research recommendations. The results of the presentations and

discussions were published by Chenoweth.

During the workshop, the panelists stressed the importance of obtaining

and using field data to establish the validity of any prediction method.

The difficulty of obtaining reliable field data was recognized, and the devel-

opment of improved methods (i.e., data banks) to acquire such data was

recommended.

Based, in part, on the results and recommendations from this workshop,

development of a bank of field data was selected as one of two program activi-

ties to be assigned to ANL. The second activity involves obtaining tube-

vibration data under controlled conditions from testing of a specially built,

industrial, size, segmentally baffled shell-and-tube heat exchanger.

III. OBJECTIVES

The DOE/ANL/HTRI Heat Exchanger Tube Vibration Data Bank has as its

immediate objective the collection of sufficient, reliable, well-documented

field data to (1) demonstrate confidence in the application of available

prediction methods to the design of equipment; (2) provide a basis for

improving these methods; or (3) provide the researcher with information for

developing new methods. The ultimate goal, in addition to reducing the

number of heat exchangers that experience detrimental vibrations, is to

minimize the number of heat exchangers that are unnecessarily overdesigned

to avoid flow-induced vibration problems.

IV. ASSESSMENT OF DIFFICULTIES

Following are some of the reasons why it may be difficult to obtain

comprehensive field data on flow-induced vibration in shell-and-tube heat

exchangers.

(1) Plant managers and field service engineers are, understandably, more

interested in getting a plant back into production than investigating the

source of vibration-induced failure of a heat exchanger.

(2) Before a vibration problem develops, there is no incentive to make

observations that could identify the source of the problem. Thus, although a

long-term phenomenon may have caused the failure, recent operational changes

are usually suspected.

(3) Actual operating conditions often do not agree with conditions

assumed in the design of a heat exchanger, particularly during startup,

shutdown, and plant upsets. It is reasonable to suspect many vibration

problems are initiated during these phases of operation.

(4) Flow velocity profiles within a tube bundle and tube damping, both

important parameters in any prediction method, are difficult to measure and

to calculate.

(5) Records are seldom kept of "as built" heat exchangers. Deviations

during initial construction and subsequent field changes are not always noted

on drawings.

(6) Before organizations will release the desired amount of' data, they

must be assured that its source will be protected and that its use will be

restricted to evaluation of prediction methods.

The last item was a contributing factor in the decision to assign an

independent, non-government organization (i.e., HTRI) the task of collecting,

storing, and coding the data forwarded to ANL.

V. DATA FORM

It is important that the data be collected in a systematic way, be as

complete as possible, and as accurate as practical. Toward this end, a

standard questionnaire is required which lists the desired information that

may be available but may not be considered significant by each contributor.

The questionnaire should provide entries for sufficient primary data

to enable an investigator (1) to calculate important derived data such as

flow velocity fractions and natural frequencies (if not measured); (2) to input

the data in various predition methods; (3) to compare the calculated results

with actual performance; and (4) to request additional information that may

be made available by the source.

The DOE/ANL/HTRI Heat Exchanger Tube Vibration Data Form and Instruction

Sheet developed to satisfy these requirements are reproduced in Appendix 1.

The 4-page data form is based on a Heat Exchanger Vibration Data Sheet

developed and used by HTRI to accumulate their data bank. In consultation

with HTRI, the format of their data sheet has been rearranged and enlarged

to motivate and accommodate more input, particularly with respect to

vibration damage description, analysis of two-phase flow, and evaluation of

the influence of axial forces on tubes.

As the case histories are received by HTRI, they will be coded. Page 1

of the Data Form will be retained in a confidential file. Pages 2, 3, and 4,

which contain the pertinent technical information will be sent to ANL for

inclusion in the DOE/ANL/HTRI Heat Exchanger Tube Vibration Bank.

VI. SOLICITATION

As discussed above, the task of soliciting case histories has been

assigned to HTRI. The letter of solicitation that accompanies the data

form is included in Appendix 1.

A direct solicitation for case histories has been made to HXRI member

organizations (> 150) located through the world. Additionally, non-HTRI

member organizations will be solicited.

The vibration problem is sufficiently complex, that a follow-up procedure

will be implemented to ensure complete documentation of each case history. In

addition, the quality of the information will be evaluated; poor data with

inadequate documentation will only be misleading. It is better to have fewer

reliable data in a data bank than a larger amount of questionable data.

VII. INITIAL CASE HISTORIES

Fifteen of the most representative of well-documented case histories have

been purchased from the HTRI Data Bank, and the information transferred to the

new data forms. These forms are reproduced as Appendix 2, and represent the

initial case histories of the DOE/ANL/HTRI Heat Exchanger Tube Vibration Data

Bank. Owing to the enlarged format and increased number of entries, there are

areas where the data are incomplete.

Also included in Appendix 2 is a summary tabulation of the geometries and

various process fluids of the heat exchangers.

VIII. DISCUSSION

Successful development of a data bank of heat exchanger tube vibration case

histories cannot be guaranteed a priori because of the many difficulties in

obtaining data that are sufficiently detailed and reliable. For the most part,

these difficulties are beyond the control of the data bank developer. In fact,

some investigators who have attempted to assemble a similar bank for evaluation

of prediction methods have concluded that such an effort, while initially

appealing, is difficult to accomplish in practice because of inherent un-

certainties in the data.

Nevertheless, development of the DOE/ANL/HTRI Heat Exchanger Tube Vibration

Data Bank is deemed a significant effort toward a better understanding of the

phenomena involved, and marked improvement in formulation and application of

prediction methods.

More specifically: Although information in the data bank will be pre-

dominantly of a qualitative nature, it will aid researchers and design

engineers in (1) identifying regions within a tube bundle (such as the first

row after the baffle cut) that are most susceptible to vibration and whether

the mode of failure is tube wear at the baffle or intertube impacting; and

(2) determining the relative effectiveness of various design features (e.g.,

impingement plates) in reducing the potential for tube vibration.

As a source of practical information, the data bank will be particularly

beneficial to researchers who have no direct experience in design or operation

of heat exchangers, but are involved in development of design guidelines and

corresponding performance-prediction methods.

For the effort to be successful will require the cooperation of the con-

tributors to the bank to ensure that complete and accurate data are provided.

Also, it will be necessary to collect case histories from heat exchangers that

have as well as those that have not experienced vibration problems, and from

units with liquids, gases, and two-phase mixtures as the shellside fluid. As

the number of respective case histories increases, trends in the dynamic

behavior will become apparent, as will any anomalies that should be disregarded

because of inaccurate or uncertain data. As necessary, selected case histories

will be followed up with personal contacts and/or on-site visits for purposes

of obtaining clarification or additional information.

It is not unreasonable to expect that it will take several years to

collect a sufficient number of well-documented cases for the data bank to

become a useful tool in the evaluation of prediction methods. However, during

this time period the available data will provide useful guidance of research

efforts. For example, new methods to calculate flow velocities may be derived

which will increase the potential usefulness of the data over what it would

be today.

APPENDIX 1

HTRI Solicitation Letter for Tube Vibration Case Histories

and

DOE/ANL/HTRI Heat Exchanger Tube Vibration Data Form

HEAT TRANSFER RESEARCH, INC. Research Facilities

1000 South Fremont Avenue Alhambra. California 91802 Telephone <213) 570-3950Telex 67-4888 (CFORAUN) TWX 910-589-3377

Subject: Tube Vibration Data Bank on Shell-and-Tube HeatExchangers

The importance of correctly predicting, and thus eliminating, the danger of possible tube vibration in shell-and-tube heatexchangers hardly needs to be emphasized. There are many known cases where tube vibration resulted in destruction oftubes with very dangerous and costly consequences. HTRI has been active in tube vibration research for the past eight years.

In October 1976 HTRI organized under contract to ERDA (presently US Department of Energy, DOE) a Tube VibrationWorkshop with a pane! discussion on the state of the art by selected international experts. (Reference ERDA Report No.SAN/1273-1.) One of the principal conclusions was the urgent need for a tube vibration data bank. To test the variouspredictive methods developed from theory or laboratory studies, field data on large-scale industrial shell-and-tube heat ex-changers are necessary. Our subsequent contract with DOE resulted in

• HTRI consulting on a research program involving a large-scale test exchanger for vibration study at the Argonne Nation-al Laboratory. This test is currently under way and is producing most important data. The results will eventually bepublished as a report from Argonne National Laboratory and will also be made available to the International EnergyAgency.

• HTRI, acting on behalf of DOE/Argonne. soliciting and collecting data for a new DOE/ANL/HTRI Heat ExchangerTube Vibration Data Bank.

The reason Argonne National Laboratory has given the task of establishing the Tube Vibration Data Bank to HTRI is (a) ourprevious experience in the proper assembly of tube vibration data, and (b) to assure anonymity of the data sources.

By this letter 1 am requesting support from your company to supply field data on shell-and-tube heat exchangers that experi-enced vibration problems as well as data on similar exchangers that did not experience vibration problems. Such cases to beuseful need to be reasonably well documented. A new Data Form (attached) was developed to assist in collecting the data. Itreflects our experience and anticipates items that are significant but might be overlooked. The identity of the data sourcewill be confident..! to HTRI Staff as only pages 2, 3, and 4 of the Data Form will be included in the Data Bank. Yourcooperation will assure that badly needed data will be available for a well-organized international cooperative project onflow-induced vibration and ultimately the formulation of improved methods for tube vibration prediction.

Sincerely yours,

JT:pth Jerry TaborekAttachment Technical Director

Administrative Office

1 - 2 ' * " Huntington Drive. Suite 309 South Pasadena. California 91030Telephone (213) 670-3980 Telex 67-5355 (HTRI)

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM Pagel

Name of Person

Submitting Case

Photic Number

Address

(Confidential)

Item No.

Reference No.

(Coiilidtnlial)

(Confidential)

Assigned

Case No.

Date Submitted

INSTRUCTIONS

HTRI is collecting data on vibration and vibiation damage in shel!-and-tubc heat exchangers which will be incorporated

into a Vibration Data Bank sponsored by the U. S. Department of Energy (DOE). Some years ago, TEMA and HTRI

collected case studies of vibration which have become the initial entries in the data bank. Recognizing that more

comprehensive data are needed, this data collection form has been prepared. The case studies will be used to test and to

aid in the improvement of proposed correlations for predicting the occurrence of vibration and possible damage which

might result. Until a sufficiently broad data bank can be assembled and used to test possible prediction methods, it will

be impossible to make predictions w :iy degree of confidence.

Any predictive method must not only indicate when vibration problems are probable, but must also predict accurately

when they will be absent. Consequently, we are interested in also receiving a number of cases of heat exchangers which

did not experience vibration and yet were similar to ones which had vibration problems. Much of the requested infor-

mation may be available from drawings and/or specification sheets for the exchangers. If these are supplied, only the

flow conditions and observed descriptions of damage, vibration frequencies, etc. need be filled in on the data sheets.

The company submitting the data and any Item and Reference Numbers used to identify the exchanger will be confi-

dential. HTRI will assign a case number and forward the data to Argonne National Laboratory (ANL) for publication

for DOK.

Please fill in the forms as completely as possible. Supplement with photographs, sketches, drawings, and descriptions

if available. Indicate known deviation from construction drawings. Add anything you feel would assist in under-

standing flow-induced vibration, For the benefit of all. please contribute as many cases as possible. Mail the completed

forms with attachments to:

Heat Transfer Research, Inc.

1000 S. Fremont Avenue

Alhambra.CA 91802

1-3

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM Page 2

AssignedCase No. .

Type • IT MA lixchanger Designation.

D Special Exchanger (Describe) —

Shell Orientation —I Horizontal

D Vertical

SHELL GEOMETRY (Complete Sketch Below) TUBE GEOMETRY

Inside Diameter, mm (in.)_

Wall Thickness, mm ( in . )_ Material.Inlet Nozzle ID. i n n (in.) „

Outlet Nuzzle II). nun (in.).

Impingement Protection D No

(Describe >

Annular Distributor O No

Open Cut Area mm2 (in.2)

DYe

QYes

Nozzle-to-First Tube Row Distance, mm (in.)_

CROSS BAFFLE GEOMETRY

Type D Segmcntal: D Double-Segmental D Disc/Doughnut

• I liplc-Segmental: D No-Ttihes-in-Window

Baffle Cut, % Shell Diameter

Cut Orientation Relative to Axis oflnlet Nozzle

Inlet Baffle D Perpendicular D Parallel D 4 5 "

Central Baffles O Perpendicular DParallel f_45"

Baffle Thickness, mm (in.) Material

Diametral Clearances Shell-to-baffle, mm (in.)

Tubc-to-baflle mm (in.) .

Uundle-to-shcll, mm (in.)

Number of Baffles Along Length of Shell

Baffle Spacing, mm (in.) Central

inlet Outlet

Unsupported Tube Span Lengths, mm (in.).

Longest Inlet Outlet —

. Material.

Outside Diameter, mm (in.) .

Wall Thickness, mm (in.)

Tube lengths

Straight Tube. Inside Tuhcslu'ets. mm (in >

11-lube. I iibcsliivl to I ti.ii tl l.nigciil. Him (in.)

Tube Pilch, mm (in.) _

Layout (Please Circle)

Flow 2_

No. of Tubes No. ofTubepasses.

First Tubepass Q Countercurrent D Cocurrent

Tube-to-Tubesheet Joint

O Welded • Roller Expanded • Other

If U-Tube

Maximum Bend Radius, mm (in.)

Bend Orientation Relative to Axis of Shellside Inlet Nozzle

D Perpendicular D Parallel

If Bend Supported, Describe in Comments Below

If Finned Tubes

Fins/m (Fins/in.) Fin Material

Diameter, mm (in.). Root Over Fins

II Fnlianceil Surface Tubes

(Describe).

DETUNING BAFFLE

If Detuning Baffle Used to Control Acoustic

Vibration. Indicate Position on Sketch Below

COMMENTS AND SKETCH

Complete sketches by drawing in tubeside and shellside nozzles.

Indicate inlet nozzles with an arrow.

.a.Fixed Tubesheet

......J L

fJ . . . J

ndicate top of exchanger as mounttd

*>y filling In appropriate arrow. 1-4

Show sht llside Inlet nozzle location, baffle cut

orientation, and impingement devices.

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM

Page 3

Assigned

Case No..

PROCESS CONDITIONS

Flow Rale. kg/s(!03lb/hr)

Inlet Temperature, C (F)

Outlet Temperature, C (F)Inlet Pressure. kPa (psia) Absolute

iîsurolMPTkPTi (psi)Inlet Wciphl l'i:iction Vapor

Outlet Weifjlu Fraction Vapor

Vibration Observed

Reference Condition A

Tubeside Shellside

DNo DYes

Reference Condition B

Tubeside SheUside

DNo O Yes

FLUID PHYSICAL PROPERTIES

Fill In All Applicable Entries

Fluid NameReference Temperature, C (F)

Tubeside

7 ' "~

Shellside

ILiquid Properties at ReferenceTemperatures

Density, kg/m3 (lb/ft3)Viscosity. tnPa-s (cP)Thermal Conductivity, W/m-C (Btu/m ft F)Heat Capacity, kJ/kg-C (Btu/m ft F)

. — „._

Vapor or Gas Properties atReference Temperatures

Density, kg/in3 (lb/ft3)Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/hr ft F)Heat Capacity, kJ/kg-C (Btu/lb F)Fluid Molecular Weight, kg/mol fjb/mole)

If Boiling or CondensingLatent Heat, kJ/kg (Btu/lb) 1

1-5


Aligned

Cite No. .

VIBRATION AND DAMAGE DESCRIPTION

When Vibration Present, Shcllside Flow Rale, kg/s (103 Ib/hr)

If Known. Crossflow Velocity at baffle tip. in/s (ft/sec)*

Crossflow Velocity at centerline, m/s (ft/sec)*

Velocity Through Window in Baffle, m/s (ft/sec)*

Inlet Nozzle Velocity, m/s (ft/sec)*

Outlet Nozzle Velocity, m/s (ft/sec)*

Measured Natural Frequency, Hz

Measured Acoustic Frequencies, Hz

Noise Sound Level, db

' Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources D No D Yes

Source Frequency. Hz.

• Machinery

D Cavitation

rpm

• Piping

D Pulsating Flow

Damage Noted

Type

D

aaD

No

Yes (

Tube-to-Tube

Tube-to-Sheil

Zomple

Impact

Impact

Wear

Complete sketch at bottom of page indicating location in bundle

O Cutting at Baffle D Near Tubesheet

O Tubeshect Joint Leaking D Fatigue

D One Side of Tubes Only • Parallel to Flow P Normal to Flow

D All Around Tube Circumference• Corrosion Evident • Fouling Evident

Q General Description of Damage

Exchanger Operation History

How Long on Stream Before Damage Occurred?

Any Unusual Occurrence Observed Prior to Vibration as a Consequence of

D Start-up D Plant-Upset D Shutdown

Describe

* If Vibration Remedy Applied, Describe and Indicate Results:.

TUBE BUNDLE DAMAGE SKETCH

n

u1-6

APPENDIX 2

Case Histor ies 101-115 of the DOE/ANL/HTRI Tube Vibration Data Bank

Summary of Heat Exchanger Case Histories in Appendix 2

CawNo.

101

102

103

104

105

106

107

101

109

110

111

112

113

114

115

SnellT y p e *

8EM

BJM

AEP

AES

AET

AET

CEM

CEM

CEM

CEiN

CEN

AJS

AEU

AEL

BJS

BaffleType

Seg.

Seg.

2-Seg.

Seg.

Seg.

Seg.

2-Seg.

3-Seg.

2-Seg.

2-Seg.

2-Seg.

Seg.

Seg.

2-Seg.

Seg.

BundleType

FXTS

FXTS

OPFH

SRFH

PTFH

PTFH

FXTS

FXTS

FXTS

FXTS

FXTS

PTFH

U-lUtW

FXTS

PTFH

TubeOOIn.

0.750

0.750

0.625

0.625

0.98*

0.98*

0.750

0.750

0.750

1.00U

1.00C

0.750

0.750

0.750

0.750

TubePilchRatio

U3

1.25

1.20

1.20

1.28

1.2S

1.25

1.25

1.33

1.25

1.33

1.33

1.25

1.67

LayoutAneU

deg.

30

60

30

30

60

60

60

60

60

45

45

90

90

60

90

TubesMeFluid

City Gas

Water

Water

Water

Water

Water

Nafl Gas

Nafl Gas

Naf> Gas

Water

Water

Water

Water

Rich Gas

Water

ShellsldeFluid

City Gas

Refrlf.

water

Air

City Gas

Nafl Gas

Nafl Gas

Nafl Gas

CHefln

OUfln

Air

H.C.

Lean Gas

Proc. Gas

SMIIDiameter

in.

47.2

44.0

19.3

10.1

57.7

57.7

37.0

44.0

53.0

45.0

45.0

43.0

na56.0

69.0

Damage Reported

Noise

Baffle

CoHMon

Baffle

Near Tunesneet

Baffle

Tubejolnt

Baffle

Tubejolnt

Baffle

Near Inlet

Noise

For definitions, see Standards of Tubular Exchanger ManufacturersAssociation, Sixth Edition, 1978.

2-2


To protect the identity of the organization submitting this case, HTRI has

assigned a case number. Additionally the data on pages 2 , 3 , and 4 have been

reviewed to ensure that they do not include any propietary information.

This is a replacement for the original page 1 that provides space for

additions] commnnts, drawings, photographs, etc.

Assigned

Case No. 101

Summary

This 48-in. diameter by 13-ft long BEM TEMfl style heat exchangerwith segmental baffles had "city gas" in both the shell side andthe tube side! Although no direct damage to the tubes was noted,there was a loud noise during operation. The noise was assumedto have been the result of flow-induced acoustic vibration.Information is limited to that presented on data form.

2-3


Assigned

Case No. 101

Type B TEMA Exchanger Designation.D Special Exchanger (Describe)—

Shell Orientation ^HorizontalD Vertical


Inside Diameter.Am (in.) W1.2.Wall Thickness, mm (in.) MaterialInlet Nozzle ID.wm (in) 1 0Outlet Nozzle ID.wm (in.) lO

Impingement Protection JLNo(Describe)

• Yes

Annular Distributor U N oOpen Cut Area mm* On.2)

OYes

Nozzle-to-First Tube Row Distance, mm (in.)


Type tfSegmental; • Double-Segmental D Disc/Doughnut

O Triple-Segmental; Q No-Tubes-in-WindowBaffle Cut, % Shell Diameter £Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle ^Perpendicular D Parallel D 4 5 °Central Baffles pCPerpendicular D Parallel O45 O

Baffle Thickness,am (in.) MaterialDiametral Clearances Shell-to-baffle,«H»I (in.)

Tube-to-baffle«m (in.) 0>Q\Bundle-to-shell,«w (in.) II

Number of Baffles Along Length of Shell.Baffle Spacing,-mm (in.) Centra! _

Inlet ^1.~> Outlet

Unsupported Tube Span Lengths,-mm (in.)Longest _ ^ H _ Inlet 7 1 . ^ Outlet 7 7 . S

Outside Diameter.-mm (in.) !Wall Tliickness.tnnr(in.)^-P7£7_ Material 3QH3&.Tube Lengths

Straight Tube, Inside Tubesheets.mm (in.) I !>3U-Tube, Tubesheet to Bend Tangent, mm Cm.)

Tube Pi tch ,** (in) \'<K>

Layout (Please Circle

Flow

No. of T u b e s -First Tubepass D Countercurrent DCocurrentTube-to-Tubesheet Joint

1» Welded D RoUer Expanded D OtherIfU-Tube

Maximum Bend Radius, mm (in.) rmZ

No. ofTubepasses.

Bend Orientation Relative to Axis of SheUside Inlet NozzleO Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Fins/m (Fins/in.) , Fin Material _ZZH^Diameter, mm (in.), Root — Over F»«w

If Enhanced Surface Ttihw

(Describe).

DETUNING BAFFLE


Vibration, Indicate Position on Sketch Below

COMMENTS AND SKETCH

Complete sketches by drawing In tubeside and sheilsld* nozzles.


Fixed TubeshMt

uI Indicate top of exchanger at mounted

by inline In appropriate arrow. 2-4

Show stwllslde Inlet nozzle location, baffle cut



Assigned

Caw No. . 101

PROCESS CONDITIONS

Flow Rate, fcg/*(103lb/hr)

Inlet Temperature, €-(F)

Outlet Temperature, e (F)

Inlet Pressure, fcPa (psia) Absolute

Measured AP,kP»(ps) CAccuLATeOInlet Weight Fraction Vapor

Outlet Weight Fraction Vapor

Vibration Observed


Tubeade

7

b<\.%

370

1.01.0

ShetUde

yiM

3700.«J1.01-0

D No BYes


Tubeade SfcdbMe

O No Q Yes



Fluid Name

Reference Temperature ~&(F)

Tubeside

" c u r G/»s"

Shdlside

"ciTr CrA<?

Liquid Properties at Reference

Temperatures

Density, kg/ni3 (lb/ft3)

Viscosity, mPa-s (cP)

Thermal Conductivity, W/m-C (Btu/m ft F)

Heat Capacity, kJ/kg-C (Btu/m ft F)

Vapor or Gas Properties at

Reference Temperatures

Density, fcg/w3 (lb/ft3)

Viscosity, roftfo (cP)

Thermal Conductivity, W/m-G- (Btu/hr ft F)

Heat Capacity,-kJ/kg-G- (Btu/lb F)

Fluid Molecular Weight, Jsg/»M>KIb/mole)

O.Sl

If Boiling or CondensingLatent Heat, tel/fcg (Btu/lb) | j

o.2zs0.0 (fh

2-5


AnfcaedCafe No.. 101


When Vibration Present, Shellside Row Rate, kg& (103 Ib/hr) \%HIf Known, Crossflow Velocity at baffle tip,-«A (ft/sec)*

Crossflow Velocity at centerline, «/*<ft/sec)*

Velocity Through Window in Baffle, •»/* (ft/sec)*

Inlet Nozzle Velocity, tn/s (ft/sec)*

Outlet Noulc Velocity.




« Please describe how velocities were calculated or estimated. COMpt/tfcfc

Vibration Caused by External Sources B.No OYes

Source Frequency, Hz.

D Machinery

D Cavitation

. rpm.D Piping

D Pulsating Flow

Damage Noted

Type

Wear

t? No

DYes Complete sketch at bottom of page indicating location in bundle

D Tube-to-Tubc Impact

Q Tube-to-Shell Impact

O Cutting at Baffle

D Tubesheet Joint Leaking

D One Side of Tubes Only D Parallel to FlowD All Around Tube CircumferenceD Corrosion Evident D Fouling EvidentQ Genera! Description of Damage .

O Near Tubesheet

Q Fatigue

D Normal to Flow





Describe

If Vibration Remedy Applied, Describe and Indicate Results:


)

2-6

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM h g e l

To protect the identity of the organization submitting this case, HTRI hasassigned a case number. Additionally the data on pages 2 , 3 , and 4 have beenreviewed to ensure that they do not include any propietary information.This is a replacement for the original page 1 that provides space foradditional comments, drawings, photographs, etc.

AssignedCase No. 102

Summary

This 44-in. diameter by 12-ft long BEJ TEMA style heat exchangerwith segmental baffles had propylene vapor on the shell side andcooling water on the tube side. The vapor entered the shellthrough the double nozzles. The vapor was cooled but not con-densed. Tube damage was noted as cutting at the baffles; however,the specific location in the bundle was not noted. Informationis limited to that presented on data form.

2-7

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM F>te2

AssignedCaw No. . 102

Type S TEMA ExchangerD Special Exchanger

Designation.(Describe)—

BJM Shell Orientation IJ HorizontalO Vertical


Inside Diameter,tnm (in.)Wall Thickness,-mm (in.)Inlet Nozzle ID, mm (in.)

MaterialJLf2_

2HOutlet Nozzle ID,»m (in.)

Impingement Protection B No(Describe) = T

D Yes

Annular Distributor SfNo OYesOpen Cut Area mm2 (in.2)

Nozzle-to-First Tube Row Distance, mm (in.)_


Type HSegmental; O Double-Segmental O Disc/Doughnut

D Triple-Segmental; D No-Tubes-in-WindowBaffle Cut, % Shell Diameter '4bCut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle • Perpendicular B Parallel D45°Central Baffles • Perpendicular HTarallel D45°

Baffle Thickness, mm (in .)Al£i2S. MaterialDiametral Clearances ShelS-to-baffle, mm (in) O.Vlh

Tube-to-baffle mm ( in) O.O\St>lS

Bundle-to-shell, Rwn-(in.) QJS&

Number of Baffles Along Length of Shell HBaffle Spacing, nm (in.) Central ?fe-?

Inlet 1Q>~fh Outlet 1±

Unsupported Tube Span Lengths, mm (in.).Longest_£iii2i- Inlet b^Hb Outlet_

Outside Diameter, n»m(in.) d.'t'i/iWall Thickness,-m» ( in) O.OfeC Material AQMlgAlTVTube Lengths

Straight Tube, Inside Tubesheets.ami (in.).U-Tube, Tubesheet to Bend Tangent,«H» (in.).

Tube Pitch, mm (in.) !Layout (Please Circle)

now 2<£.£No. of Tubes No. of Tubepasses.First Tubepass B Countercunent JB CocurrentTube-to-Tubesheet Joint

D Welded B Roller Expanded D OtherIfU-Tube

Maximum Bend Radius, mm ("» ) '—Bend Orientation Relative to Axis of Shellside Inlet NozzleD Perpendicular • ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Fins/m (Fins/in.) ~ Fin MaterialDiameter, mm (in.), Root ~ Over Fins

If Enhanced Surface Tubes ZZ^

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Comptete sketches by drawing In tubeslde and shellside nozzles.

Indicate Inlet nozzles with an arrow.

mFixed TubeshMt

FT

JLX

c-t Indicate top of exchanger as mounted

by filling In appropriate arrow. 2-8

Sliow shellsldc Inlet nozzle location, baffle cut

orientation, and Impingement devices.


AssignedG - e N o

PROCESS CONDITIONS

Flow Rate, kgM103lb/hr)Inlet Temperature, e ( F )Outlet Temperature, € (F)Inlet Pressure, W t (psia) AbsoluteMeasured AP,-J#»(p$i)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed


Tubeade

i

7 b\in

• Z..Vo0

SheUade

CM,192\00136,H.O1.01.0

O No «Yes

Refetcmce Coaditioa B

Tubeade ShdUde

O No Q Yes



Fluid NameReference Temperature ,€-(F)

Tubeside

Coot-lfJC WATtK

Shdlsde

(00Liquid Properties at ReferenceTemperatures

Density.-kg/m3 (Ib/ft3)Viscosity, mP«*«- (cP)Thermal Conductivity, W/m-€ (Btu/m ft F)Heat Capacity ,W/kg«€ (Btu/m ft F)


Density,*fif"3 (lb/ft3)Viscosity,-mP«*s (cP)Thermal Conductivity^W/m-C (Btu/hr ft F)Heat Capacity, ktflt%-€ (Btu/lb F)Fluid Molecular Weight, kg/mt* Ob/rr ale)

>o.ooS? 0.0CRS

If Boiling or CondensingLatent Heat, ktykg (Btu/Ib) | j

2-9


Caw No.. 102


When Vibration Present, Shellside Flow Ra te ,kgHl° lb/hr) felfeIf Known. Crossflow Velocity at baffle tip, m/fr(ft/sec)*

Crossflow Velocity at centerline, mft (ft/sec)*Velocity Through Window in Baffle, m/* (ft/sec)*Inlet Nozzle Velocity, «/s-(ft/sec)*

Outlet Nozzle Velocity ,-mh (ft/sec)*


Measured Acoustic Frequencies, HzNoise Sound Level, db


Vibration Caused by External Sources DNo D Yes


• Machinery• Captation

D PipingD Pulsating Flow

Damage Noted

Type

Wear

D No

XYes Complete sketch at bottom of page indicating location in bundle

• Tube-to-Tube ImpactO Tube-to-Shell Impact

^Cutting at BaffleD Tubesheet Joint Leaking

D One Side of Tubes Only • Parallel to FlowD All Around Tube CircumferenceD Corrosion Evident • Fouling EvidentD General Description of Damage

D Near Tubesheeta Fatigue

D Normal to Flow


• How Long on Stream Before Damage Occurred? .

• Any Unusual Occurrence Observed Prior to Vibration as a Consequence ofD Start-up P Plant-Upset D Shutdown

Describe

» If Vibration Remedy Applied, Describe and Indicate Results:


2-10


To protect the identity of the organization submitting this case. HTRI has




additional comments, drawings, photographs, etc.

Assigned

Case No.103

Summary

This 20-in. diameter by 7-ft long AEP TEMA style heat exchangerwith segmental baffles had water on both the shell side and thetube side. The inlet nozzle orientation was such that itscenterline intersected the baffle cut at 45°. The baffle cutwas 45 percent of the shell inside diameter which results inlittle crossflow. The tube damage reported tube-to-tube inrpactresulting in splitting of the tube material until leaks de-veloped. Information is limited to that presented on data form.

2-11

DOE/ANL/HTRf HEAT EXCHANGER TUBE VIBRATION DATA FORM

Type 4 TEMA ExchangerO Special Exchanger

Designation(Describe)

ACP

AssignedCase No.

Shell Orientation

103

H HorizontalD Vertical


Inside Diameter,-mm (in)Wall Thickness, «wt (in.) Material

L2\1

Inlet Nozzle ID, tarn (in.)_Outlet Nozzle i n - — ( i n )

Impingement Protection MTNo(Describe)

O Yes

Annular Distributor fit No Q YesOpen Cut Area mm* (in.8)

Nozzle-to-First Tube Row Dist»nce,-mm (in.) t «


Type ASegmental; O Double-Segmental Q Disc/Doughnut

a Triple-Segmental; O No-Tubes-in-WindowBaffle Cut, % Shell Diameter )iS.Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle D Perpendicular • Parallel B 4 S °Central Baffles D Perpendicular Q Parallel R 4 5 °

Baffle Thickness,-mm (in.) JUiEz. MaterialDiametral Clearances Shell-to-baffle, «w* (in.)_£xAiL

Tube-to-bafflemw (in.)Bundle-to-shell, mm (in) LM\L

Number of Baffles Along Length of Shell.Baffle Spacing,#WJ (in.) Central

Inlet U Outlet 1LUnsupported Tube Span Lengths, mm (in.).

Longest _ ! i ! L _ Inlet Outlet _

0.MSOutside Diameter, mm (in.)Wall Thickness, «MI (in )O'0 tflTube Lengths

Straight Tube, Inside Tubesheets, — - ( i n ) *&*<*U-Tube, Tubesheet to Bend Tangent,*m (in.)

Tube Pitrh,«f( in.) O.1SQ


Flow

No.ofTubes_H01 . No. of Tubepasses.First Tubepass D Countercunrent D CocurrentTube-to-Tubesheet Joint

O Welded XRoller Expanded O OtherIfU-Tube

Maximum Bend Radius, mm (•")Bend Orientation Relative to Axis of Shelhide Inlet NozzleD Perpendicular O ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Fins/m (Fins/in.) ~ Fin MaterialDiameter, mm (in.), Root Over Fins

If Enhanced Surface Tubes *~~

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing In tubesla* and stieJJslde nozzles.Indicate Inlet nozzles with an arrow.

Fixed Tubesheet

11 ^ Indicate top o* exchanger a* mounted


Show stullslde Inlet nozzle location, baftt* cutorientation, and Impingement devices.

OF •DG

OOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM

Assigned

Cue No. _ J ° L

PROCESS CONDITIONS

Flow Rate, kg/t-(103lb/hr)Inlet Temperature,C(F)Outlet Temperature, C(F)Inlet Pressure, kPa-(psia) AbsoluteMeasured AP.hfti(psi)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed


Tubeade Sheuale

2oo

0

oDNo flYes


Tubeade Shdade

D No D Yes



Fluid NameReference Temperature, C (F)

Tubeside Shellside

Liquid Properties at ReferenceTemperatures

Density, kg/m3 (lb/ft3)Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/m ft F)Heat Capacity, kJ/kg-C (Btu/m ft F)


Density, kg/m3 (lb/ft3)Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/hrftF)Heat Capacity, kJ/kg-C (Btu/lb F)Fluid Molecular Weight, kg/mol Ob/mole)

y \

\

s

If Boiling or Condensing / V ^ ^y^ ' s \ v

Latent Heat, kJ/kg (Btu/lb) \yS ^"S^L"""^ ^

2-13


Att«MdCaseNo.. 103


When Vibration Present, Shelkide Row Rate, kgfc (103 lb/hr) QOOIf Known, Crossflow Velocity at baffle tip, m/s (ft/sec)*

Crossflow Velocity at centerline, m/s (ft/sec)*Velocity Through Window in Baffle, m/s (ft/sec)*Inlet Nozzle Velocity, m/s (ft/sec)*Outlet Nozzle Velocity, m/s (ft/sec)*

Measured Natural Frequency, HzMeasured Acoustic Frequencies, Hz

Noise Sound Level, db1 Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources DNo O Yes


D Machinery

O Cavitation

. rpm.D PipingD Pulsating Flow

Damage Noted

Type

Wear

O No

/STYes Complete sketch at bottom of page indicating location in bundle

XTube-to-Tube ImpactD Tube-to-Shell Impact

O Cutting at BaffleD Tubeshcet Joint Leaking

D One Side of Tubes Only D Parallel to FlowD All Around Tube CircumferenceD Corrosion Evident O Fouling EvidentD General Description of Damage

• Near Tubesheet• Fatigue

D Normal to Flow



• Any Unusual Occurrence Observed Prior to Vibration as a Consequence ofD Start-up O Plant-Upset D Shutdown

Describe

* If Vibration Remedy Applied, Describe and Indicate Results:.


2-14


To protect the identity of the organization submitting this case. HTRI hasassigned a case number. Additionally the data on pages 2, 3, and 4 have beenreviewed to ensure that they do not include any propietary information.This is a replacement for the original page 1 that provides space foradditional comments, drawings, photographs, etc.


Summary

This 10-in. diameter by 6-ft long AES TEMA style heat exchangerwith segmental baffles had air on the shell side and water onthe tube side. The inlet nozzle orientation was such that itscenterline intersected the baffle cut at 45°. The baffle cutwas 45 percent of the shell inside diameter which results inlittle crossflow. All tubes showed evidence of cutting at eachbaffle. It was noted that there was a possibility that thevibration might have been induced by outside sources. Inform-ation is limited to that presented on data form.

2-15

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM P * e 2

AssignedCase No. . 104

Type 0 TEMA Exchanger

D Special Exchanger

Designation

(Describe)

Shell Orientation • HorizontalWOT GIVEM OVertical


Material.

Inside Diameter, nm-(in.)Wall Thickness.-mm (in.)

Inlet Nozzle ID, mm (in) S _Outlet Nozzle ID, mm (in) b

Impingement Protection B N o DYes(Describe) ___.~ir

Annular Distributor JQNo OYes

Open Cut Area mm* (in.2)

Nozzle-to-First Tube Row Distance, nwr(in.)_


Type J^Segmental; D Double-Segmental D Disc/Doughnut

O Triple-Segmental; Q No-Tubes-in-Window

Baffle Cut, % Shell Diameter ^

Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle O Perpendicular • Parallel )sf450

Central Baffles D Perpendicular • Parallel ^ 4 5 °

Baffle Thickness,•urn (in.) JL23?MaterialDiametral Clearances Shril-tn-hafflp m».(in ) O.OÔ

Tube-to-baffle mm (in) O.Q\°i

Bundle-to-shell, mm (in.) '

Number of Baffles Along Length of Shell 6.Baffle Spacing, aw*(in.) Central <Q

Inlet IP Outlet I P

Unsupported Tube Span Lengths, mm- (in.).Longest 10 Inlet T~O Outlet_

Outside Diameter, mm (in.) !

Wall Thickness, mm (in) 0 .0t>£ Material "lO/fQ C O Mi

Tube LengthsStraight Tube, Inside Tubesheets.-mm (in.) 10

U-Tube, Tubesheet to Bend Tangent, *nm-(in.) —

Tube Pitch, mm ( in . )_ -0.1_S>P


now ( ^ g ^No. of Tubes 1% No. of Tubep

First Tubepass D Countercurrent a Cocunent


a Welded a Roller Expanded • Other.

IfU-Tube

Maximum Bend Radius, mm (in.)

UOT


O Perpendicular D Parallel

If Bend Supported, Describe in Comments BelowIf Finned Tubes

Fins/m (Fins/in.) Fin Material *~Diameter, mm (in.). Root ~ Over Fint

If Enhanced Surface Tubes

(Describe) .

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing In tubesfde and shellslde nozzles.Indicate inlet nozzles with an arrow.

ftFixed Tubcshtat

U ^ Indicate top of exchanger as mounted


Show shellsld* Inlet nozzle location, ban la cut


Two

DOE/ANL/HTRl HEAT EXCHANGER TUBE VIBRATION DATA FORM

Assigned104

PROCESS CONDITIONS

Flow Rate, kgfa (W3]bftu)

Inlet Temperature,-€-(F)

Outlet Temperature.-e(F)

Inlet Pressure, W>( (psia) Absolute

Measured AP.-kPa (psi)

Inlet Weight Fraction Vapor


Vibration Observed


Tubeade

'<?3.7l70.C

Shellade

It*

\.o\.o

D No RYes


Tubewle

— •

SfcdWde

DNo O Yes



Fluid Name

Reference Temperature C (F)

Tubeside

M/ATEfc

Shdlside

A\({

1Liquid Properties at Reference

Temperatures

Density, kg/m3 (lb/ft3)






Density, kg/m3 Ob/ft3)Viscosity, mPa-s (cP)

Thermal Conductivity, W/m-C (Btu/hr ft F)

Heat Capacity, kJ/kg-C (Btu/lb F)

Fluid Molecular Weight, kg/mol (Ib/mole)

f Boiling or Condensing yS \

Latent Heat, kJ/kg (Btu/lb) \ / N ^ J

2-17


AlignedCateNo.. 104


When Vibration Present, Shellside Flow Rate,l«/c (103 lb/hr)

If Known, Crossflow Velocity at baffle tip,-m/t(ft/sec)»Crossflow Velocity at centerline, mf» (ft/sec)*Velocity Through Window in Baffle,-mA (ft/sec)*

Inlet Nozzle Velocity, in/* (ft/sec)*

Outlet Nozzle Velocity,*»f»(ft/sec)*

Measured Natural Frequency, HzMeasured Acoustic Frequencies, Hz

Noise Sound Level, 1

* Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources DNo DYes H R0S6i*«-£Source Frequency, Hz . rpm-

D MachineryD Cavitation

O Piping• Pulsating Flow

Damage Noted

Type

Wear

DNo

BCYes Complete sketch at bottom of page indicating location in bundle

• Tube-to-Tube ImpactD Tube-to-Shell Impact

^Cutting at BaffleD Tubesheet Joint Leaking

DNearTubesheetO Fatigue

• Normal to FlowD One Side of Tubes Only • Parallel to FlowD All Around Tube CircumferenceD Corrosion Evident D Fouling Evident• r.pin-ralrVwriptinnnfnamay ftLl T(Jf,£"4 f )HO(JgP £\IWPk)C£ OP

~JTTiAl£- AT EACH


• How Long on Stream Before Damage Occurred?.

• Any Unusual Occurrence Observed Prior to Vibration as a Consequence ofO Start-up D Plant-Upset D Shutdown

Describe .

•* If Vibration Remedy Applied, Describe and Indicate Results:


2-18

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM fage!


assigned a case number. Additionally the data on pages 2 ,3 , and 4 have been




Assigned

Case No.105

Summary

This 57-in. diameter by 12-ft long AET TEMA style heat exchangerwith segmental baffles had acetylene on the shellside and wateron the tubeside. The tube span for baffle .window tubes at theinlet and the outlet greatly exceeded the TEMA Standards formaximum spans for 1-in. carbon steel tubes. However, for thiscase no vibration was noted for the given flow rates. Informationis limited to that presented on data form.

2-19


AMfKdCase N o . . 105

Type e^TEMA Exchanger Designation A E TD Special Exchanger (Describe)

Shell Orientation J ( HorizontalD Vertical


Inside Diameter, w f i n . )Wall Thickness,mm-(in.) Material.Inlet Nozzle ID,*»m-(in.)__2l !2_Outlet Nozzle ID, mm (in.)

Impingement Protection JSfUo(Describe) Z ^

O Yes

Annular Distributor ft NoOpen Cut Area mm2 (in.2).

Q Yes

Nozzle-to-Fiist Tube Row Distance,mm(in/> V.f t


Type ^Segmental; • Double-Segmental D Disc/Doughnut

• Triple-Segmental; • No-Tubes-in-WindowBaffle Cut, % Shell Diameter 'iHCut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle D Perpendicular B Parallel D45°Central Baffles D Perpendicular ^Parallel D45°

Baffle Thickness, Mm»(in ) Oifc'Lb Material

Diametral Clearances Shell-to-baffle,««i (in) Q.Z7Tubc-to-baffle mm-(in ) 0' 01

Bundle-to-shell, «»m-(in ) a<

Number of Baffles Along Length of Shell i2_Baffle Spacing, wi«.( in.)___ Central.

inlet Outlet HQ.5fe>

Unsupported Tube Span Lengths, mm-(in.).Longest Ô.\b Inlet^6AS Outlet_

Material.Outside Diameter, iwa (in.)WaUThickness.-mm-On.;Tube Lengths

Straight Tube, Inside Tubesheets, mm (in.) 1 iH.G\U-Tube, Tubesheet to Bend Tangent, mm-(in.) —

Tube Ktch.-mm (in.) l'^<»Layout (Please Circle)

Flow

No. of Tubes No. of Tube;First Tubepass JHCountercunent •CocurrentTube-to-Tubesheet Joint

KWelded D Roller Expanded O OtherIfU-Tube

Maximum Bend Radius, mm-(in.) "**~Bend Orientation Relative to Axis of Shdlside Inlet NozzkO Perpendicular D Parallel —If Bend Supported, Describe in Comments BelowIf Finned Tubes

Finf/m (Fins/in.) Fin MaterialDiameter,-mnr(in.), Root — _ Over Fins ~

If Enhanced Surface Tubes ^

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

CompKM sk*tcn« by drawing in tutwslde and shdlsld* nozzlis.Indicate Inlet nozzles with an arrow.

Fixed Tubesheet

Indicate top of exchanger as mounted


Show snellside Inlet nozzle location, baffle cutorientation, and Impingement devices.


AssignedCase No.. 105

PROCESS CONDITIONS

Flow Rate, kg/t(103Ib/hr)

Inlet Temperature,-G-(F)

Outlet Temperature,-G<F)

Inlet Pressure, W» (psia) Absolute

Measured AP,-ki»*<psi)Inlet Weight Fraction Vapor


Vibration Observed


Tubesde

00

SbelUde

3Sl1t>\

111

1.0l.O

X N o OVes


Tubeadc SMbUe

DNo O Yes



Fluid Name

Reference Temperature -6-(F)

Tubeside

UiATfe^.

1

Shdlside

C2H2


Temperatures


Viscosity,mPa*» (cP)

Thermal Conductivity ,-W/m-€-(Btu/m ft F)Heat Capacity, IcJ/ltg-C (Btu/m ft F)




Viscosity, mPa-s (cP)Thermal Conductivity, Wfm^ (Btu/hrftF)

Heat Capacity, kJ/kg«e- (Btu/lb F)

Fluid Molecular Weight, kg/nel Qb/mole)

l . l b0.17-7

l.b-2

'.i Boiling or Condensing / " "^s^

Latent Heat, W/kg-(Btu/lb) \yS \ J

2-21


AnfenedCUe No. .

105

VIBRATION AND DAMAGE DESCRIPTION MO VI8MT10W NOTtD

When Vibration Present, Shellside Flow Rate, kg/s (103 Ib/hr)

If Known, Crossflow Velocity at baffle tip, m/s (ft/sec)*









Vibration Caused by External Sources DNo DYes

Source Frequency, Hz .

• Machinery

D Cavitation

. rpm.

D Piping

D Pulsating Flow

Damage Noted

Type

Wear

• NoDYes Complete sketch at bottom of page indicating location in bundle

D Tube-to-Tube Impact

D Tube-to-Shell Impact

O Cutting at Baffle

O Tubesheet Joint Leaking

D One Side of Tubes Only • Parallel to Flow

O All Around Tube Circumference• Corrosion Evident O Fouling Evident

• General Description of Damage

Q Near Tubesheet

D Fatigue

D Normal to Flow




O Start-up D Plant-Upset D Shutdown

Describe

If Vibration Remedy Applied, Describe and Indicate Results:.


ftLJ

2-22

DOE/ANL/HTRI HEAT EXCHANGER TUBE VfBRATION DATA FORM Pagel

To protect the identity of the organization submitting this case, HTRI hasassigned • case number. Additionally the data on pages 2,3, and 4 have beenreviewed to ensure that they do not include any propietary information.This is a replacement for the original page 1 that provides space foradditional comments, drawings, photographs, etc.

AssignedCase No.

106

Summary

This 57-in. diameter by 12-ft long AET TEMA style heat exchangerwith segmental baffles had acetylene on the shellside and wateron the tubeside. The tubespan for the baffle window tubes at theinlet and outlet were nearly the limit specified in the TEMAStandards for 1-in. carbon steel tubes. Flow-induced tube vibra-tion is indicated as the cause for tube damage near the tubesheet.Information is limited to that presented on the data form.

2-23

Type R TEMA Exchanger

D Special Exchanger


rv«gn,?tinn f\ E."J"

(TVc/rihr)

Assigned

Cue No.

raie2

106

Shell Orientation ^Horizontal

D Vertical


Sl.TsInside Diameter,-BMS (in.)_

Wall Thickness.-nm ( in . )_

Inlet Nozzle ID, mm-(in.)_

Outlet Nozzle ID, mm (in.)

Impingement Protection B^No

(Describe) '

Material.

11."DYes

Annular Distributor HNo

Open Cut Area mm2 (in.2)_

DYes

Nozzle-to-Fiist Tube Row Distance, mm-(in.) 1 - 3 7


RSegmental; D Double-Segmental O Disc/Doughnut

• Triple-Segmental; D No-Tubes-in-Window

Baffle Cut, % Shell Diameter *U


Inlet Baffle ^Perpendicular O Parallel D45°

Central Baffles j? Perpendicular D Parallel D45°

Baffle Thickness, mm (in ) O.Wb Material

Diametral Clearances Shp11-to-hafflp|.n»m.(ifi.) 0 . Z 7

Tube-to-baffle aim ( in.)_

Bundle-to-shell, mm (in.)_

Number of Baffles Along Length of Shell \

Baffle Spacing, mm (in.) Central "5H.

Inlet H M Outlet 3 ^

0,01

Unsupported Tube Span Lengths,*** (in.).

Longest J^Liia. Inlet T / . f e Outlet _J , % ! •

Outside Diameter,jnm (in.)

Wai! Thickness, mm-(

Tube Lengths

Straight Tube, Inside Tubesheets,-mm(in.)_

U-Tube, Tubesheet to Bend Tangent, mw(in.) —

Tube Pitch, «wr(in.)_JLltaLayout (Please Circle)

Flow

No. of Tubes

First Tubepas D Countercurrent D Cocunent


J? Welded D Roller Expanded D Other

IfU-Tube

Maximum Bend Radius, irmr(ui.)

Bend Orientation Relative to Axis of Shellstde Inlet Nozzle

D Perpendicular D Parallel

If Bend Supported, Describe in Comments Below

If Finned Tubes

Eim/m (Fins/in.) Fin Material

Diameter, 4«m-(in.), Root Over Pint "~*

If Enhanced Surface Tubes.

(Describe)

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing in tubeslde and shellside nozzles.Indicate inlet nozzles with an arrow.

TT

t Indicate top of exchanger as mountedby filling in appropriate arrow. 2-24

Snow sneltsld* Inlet nozzle location, baffle cutorientation, and impingement devices.


Assigned

Case No. . 106

PROCESS CONDITIONS

Flow Rate, kg!1* (103lb/hr)

Inlet Temperature,-© (F)

Outlet Temperalure,€ (F)

Inlet Pressure,-tePa (psia) Absolute

Measured AP, fcPa-(psi)



Vibration Observed


Tubemfe

1\.U

O0

SheUskte

lot

111

l.ov.O

a No BTYes


Tubeade ShdUde

• No Q Yes



Fluid NameReference Temperature -e-(F)

Tubeside Shdlside

C tHv


Temperatures

Density, kg/m3 (Ib/ft3)

Viscosity rinfe*- (cP)

Thermal Conductivity, 3K/mi€-(Btu/m ft F)

Heat Capacity,-kJ/kg-G (Btu/m ft F)




ViscosityrHiPir-s- (cP)Thermal Conductivity, WfnvG (Btu/hr ft F)

Heat Capacity, W/kg-€- (Btu/lb F)

Fluid Molecular Weight, ks/mol (Ib/mole)

\

>

yO,O\ll

I boiling or Condensing y^ "S^Latent Heat, kWcg (Btu/lb) \y/' ^ s j

2-25


AnfcaedCase No.. 106


When Vibration Present, Shellside Flow Rate, Jcg&(103 lb/hr)

If Known, Crbssflow Velocity at baffle tip,-m/s (ft/sec)*Crossflow Velocity at centerline, m/» (ft/sec)*Velocity Through Window in Baffle,-m/» (ft/sec)*Inlet Nozzle Velocity ,-mMft/se.c)*

Outlet Nozzle Velocity, m/fr(ft/sec)*

Measured Natural Frequency, HzMeasured Acoustic Frequencies, HzNoise Sound Level, db


Vibration Caused by External Sources O No G Yes


D Machinery

D Cavitation

. rpm.D Piping

D Pulsating Flow

Damage Noted

Type

Wear

O NoComplete sketch at bottom of page indicating location in bundle

D Tube-to-Tube ImpactD Tube-to-Shell Impact

O Cutting at Baffle• Tubesheet Joint Leaking

D One Side of Tubes Only D Parall. to FlowD All Around Tube CircumferenceQ Corrosion Evident D Fouling EvidentD General Description of Damage

WNear TubesheetD Fatigue

Q Normal to Flow



Any Unusual Occurrence Observed Prior to Vibration as a Consequence ofQ Start-up Q Plant-Upset D Shutdown

Describe _ _



2-26

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM h g e l

f

To protect the identity of the organization submitting this case, HTRI hasassigned a case number. Additionally the data on pages 2 ,3 , and 4 have beenreviewed to ensure that they do not include any propietary information.This is a replacement for the original page 1 that provides space foradditional comments, drawings, photographs, etc.

AssignedCase No.

107

Summary

This 37-in. diameter by 40-ft long CEM TEMA style heat exchangeris one of two in series joined by welding their shells together.The tubeside fluid, natural gas with ethylene glycol to preventhydration, passes from the one exchanger to the next withoutexternal piping. The shellside fluid, natural gas, flowscounter current and between shells through external piping.Both exchangers were identical on the shell side and bothexperienced similar tube damage in the sane locations of theexchanger. Host of the damage was noted after operating theplant at more than 40 percent higher than the designed shellsideflow. Leaking tubes were plugged. During a subsequent overhaulof the bundles, the leaking tubes were found to be "broken onside near the nozzles." It is interesting to note that thedamaged tubes were not those with the longest span at the inletend zone.

For this case, there are construction drawings and a field reportdescribing the operation history and the repairs made to theexchanger.

2-27



Type KTEMA Exchanger Designation.• Special Exchanger

CEM Shell Orientation ^HorizontalOVertical


Inside Diameter.-tiMi (in.)Wall Thickness, mm (in.)Inlet Nozzle ID.Outlet Nozzle ID, mm (in.)_

Impingement Protection Q No JK Yes

Cfi.

Annular Distributor U N o DYesOpen Cut Areaum2 (in.*)

Nozzle-to-First Tube Row Distance, «HB (in.)


Type D Segmental; J^Double-Segmental D Disc/Doughnut

O Triple-Segmental; O No-Tubes-in-WindowBaffle Cut. % Shell Diameter 3 & 3 0 ToftC O\teg.L/»0Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle D Perpendicular HParallel D45°Central Baffles Q Perpendicular fiCParallel D45°

Baffle Thickness, «w».( in . )ît l^ Material

\.S0O

Diametral Clearances Shell-to-baffle,-«»» (in) 0 . 1 % l £Tube-to-baffle <wm-(in.).. 0 ' 0 V ?fcBundle-to-shcll, JJWH (in.).

Number of Baffles Along Length of Shell ILBaffle Spacing, ami (in.) Central »> i«

Inlet *bOt<o. Outlet _

Unsupported Tube Span Lengths, mm (in.)Longest 5™ Inlet ^ ^ Outlet

Outside Diameter,-mm (in.) 0.15OWall Thickness, M (in ) CObS Material _Tube Lengths

Straight Tube, Inside Tubesheets.imw (in.)U-Tube, Tubesheet to Bend Tangent,«m-(in.)

Tube Pitch, mm ( i n . ) _ Q e S l 2 iLayout (Please Circle)

Flow 30°

No.ofTubes_l£LQ_ . No.ofTubepassesFirst Tubepass KCountercurrent DCocurrentTube-to-Tubesheet Joint NOT Gl^CN

D Welded D Roller Expanded D OtherIfU-Tube

Maximum Bend Radius, mm (•")Bend Orientation Relative to Axis of Sbellside Inlet NozzleD Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

EaHfm (Fins/in.) Fin Material —Diameter,-«WB-(in.), Root * Over Fins —

If Enhanced Surface Tubes —

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing In tubeslde and shellslde nozzles.Indicate inlet nozzles with an arrow.

-rFixed TubeshMt

J. Indicate top of exchsngtr as mounted


Show shcllside Inlet nozzle location, baft I* cut



fage 3

Assigned

Case No. . 107

PROCESS CONDITIONS

Flow Rate, fcg/s (103lb/hr)

Inlet Temperature,^ (F)

Outlet Temperaturc,-€-(F)

Inlet Pressure, Jc£a (psia) AbsoluteMeasured AP,*Eg (psi)



Vibration Observed


Tubeade

<><?I t

\OS£\O1.6

t.o

ShdUde

bllove1o1.0

1.0D No H Yes


TubesMe

SG

10 SO

\.O

ShdfaUe

210

?

i.nfSNo QYes



Fluid Name

Reference Temperature C (F)

Tubeside SheUside

NATORAL GAS


Temperatures


Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/m ft F)


^—^



Density, kg/m3 Ob/ft3)


Thermal Conductivity, W/m-C (Btu/hr ft F)


Fluid Molecular Weight, kg/mol Ob/mole)

'.! foiling or Condensing

Latent Heat, kl/kg (Btu/lb)

(

2-29


AttunedCue No. . 107


When Vibration Present, Shellside Flow Rate, kalt(103 lb/hr)

If Known, Crossflow Velocity at baffle tip,«/#-(ft/sec)»


Velocity Through Window in Baffle,-m/s-(ft/sec)*

Inlet Nozzle Velocity,-mfc (ft/sec)*

Outlet Nozzle Velocity, m/c (ft/sec)*




Vibration Caused by External Sources O Yes

Source Frequency, HE .

D Machinery

D Cavitation

. rpm.

a Piping

D Pulsating Flow

Damage Noted

Type

Wear

DNoJiYes Complete sketch at bottom of page indicating location in bundle



O Cutting at Baffle

O Tubesheet Joint Leaking

D One Side of Tubes Only D Parallel to Flow

D All Around Tube Circumference

D Corrosion Evident D Fouling Evident

JSL General Description of Damage

• Near Tubesheet

D Fatigue

D Normal to Flow

Of





Describe



2-30







Assigned

Case No.108

f

Summary

This 44-in. diameter by 40-ft long CEM TEMA style heat exchangeris one of three that are joined tubesheet to tubesheet so thatin effect the tubes are 120 ft long. The tubeside flow is naturalgas with glycol to prevent hydration while the shellside flow iscounter current and passes between shells through external piping.The bundle uses triple-segmental baffles so the shellside flow isprimarily axial. The tube spans are longer than TEMA Standardsmaximum spans for 3/4-in. carbon steel. The heat exchanger operatedsuccessfully for one and a half years at the design conditions.However, tubes beg?n leaking where they were joined to the tubesheetin all three exchangers when the shellside flow rate was sub-stantially increased beyond that used for design- The sketchbelow indicates the location of these failures. The failed tubeswere characterized by particularly long spans in the outlet endzones. Minor cutting of the tubes at the baffles was also re-ported.

For this case, there are construction drawings and a field reportdescribing the operating history, the damage noted, and therepairs made to the exchanger.

3/32"

1/8" - .

1/4"

— 3/32 V POINT OF FAILURES

-TUBE SHEET

/ •

HAND REAMED ONLYTO REMOVE SHARPCORNER.

4'

2-31


Type H TEMA ExchangerD Special Exchanger

Designation

(Describe)

CEM (FlVEp TORgSHteT)

AssignedCase No.

Shell Orientation

108

•HorizontalOVertical

\


Inside Diameter, mm (in.)_Wall Thickness, « m (in.)Inlet Nozzle ID, mm-(in.)Outlet Nozzle ID, i m (in.).

Impingement Protection(Describe)

Material__C£_

a Yes

Annular Distributor J9.NoOpen Cut Area mm* (in.2)

DYes

NozzIe-to-First Tube Row Distance, mm (in.)


Type DSegmental; D Double-Segmental D Disc/Doughnut

K Triple-Segmental; D No-Tubes-in-Window

Baffle Cut, % Shell Diameter 2£Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle • Perpendicular ^Parallel D45°Central Baffles D Perpendicular BIParallel D45°

Baffle Thickness,•swa-(in.).J2i<2?S Material C^>Diametral Clearances Shell-to-baffle,«w» (in.)_

Tube-to-baffle m (in.)_Bundle-to-shell, mm- (in.)_

Number of Baffles Along Length of ShellBaffle Spacing,-mm (in.) Central i 2

Inlet m>,G"L Outlet Wfl.i

O.

Unsupported Tube Span Lengths, MM-(in.)Longest 11AA Inlet 7 7 . 6 1 Outlet

Outside Diameter, mm (in.).Wall Thickness, m (in ) 0 . 0 6 0 Material.Tube Lengths

Straight Tube, Inside Tubesheets.-mm (in.)U-Tube, Tubesheet to Bend Tangent, mm (in.)

Tube Pitch, JWH (in.) _


Flow

No. of Tubes.

First Tubepass J^Countercurrent DCocurrentTube-to-Tubesheet Joint

D Welded KRoUer Expanded D OtherIfU-Tube

Maximum Bend Radius, wnrr (in.) ̂ _ZHI

. No.ofTubepas

Bend Orientation Relative to Axis of Shellside Inlet NozzleO Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Fint/m (Fins/in.) Fin MaterialDiameter, B»m-{in.), Root.

If Enhanced Surface Tubes. Over Fint

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches By drawing in tubeslde and shellslde nozzles.Indicate inlet nozzles with an arrow.

lout*

Fixed TubotiMt

Indicate top of exchanger » mountedby filling In appropriate arrow.

in

Show shellside Inlet nozzle location, baffle cutorientation, and impingement devices.

I


Assigned

PROCESS CONDITIONS

Flow Rate, fcg/s(103lb/hr)

InletTemperature.€-(F) / TQAlS) OP \

Outlet Temperature, €-(F) [jt, ( W <SeR|£* >Inlet Pressure, -kPft (psia) Absolute

Measured AP, kPa (psi)



Vibration Observed


Tubeade

l.O

1.0

SheOade

1,10-ISAH/HS-

l.O

l.ODNo 8 Yes


TuboJde SkeUde

D No O Yes



Fluid Name

Reference Temperaturr •€"(¥)

Tubeside

WAT'L &te> + GLVCOL

Shdlside

N4"'c S45


Temperatures




Heat Capacity, kJ/kg-C (Btu/m ft F) ^ —

^ ^



Density,Itâ3 (lb/ft3)

Viscosity,-mPfr-s (cP)

Thermal Conductivity, W/m-O (Btu/hr ft F)

Heat Capacity, fcJ/kg-6- (Btu/lb F)

Ruid Molecular Weight, kg/mol- Ob/mole)

•2.7^ -2.62

'. 3oiling or Condensing

Utent Heat.-W/fc^Btu/lb) — —

2-33

DOE/ANL/HTIU HEAT EXCHANGER TUBE VIBRATION DATA FORM

Au%nedCase No..

Par 4

108,̂


When Vibration Present, Shellside Flow Rate,fcg/s (103 lb/hr)

If Known, Crossflow Velocity at baffle tip,«/« (ft/sec)*CrossfJow Velocity at centerline,«i/s (ft/sec)*Velocity Through Window in Baffle, m/s (ft/sec)*Inlet Nozzle Velocity, »/•• (ft/sec)*

Outlet Nozzle Velocity r»A (ft/sec)'



• Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources JKNo DYes


O Machinery

D Cavitation

. rpm.D Piping

D Pulsating Flow

Damage Noted

Type

Wear

DNo

fSYes Complete sketch at bottom of page indicating location in bundle

D Tube-to-Tube ImpactO Tube-to-Shell Impact

ETCutting at Bafflelif Tubeshee! Joint Leaking

D One Side of Tubes Only D Parallel to Flow• All Around Tube CircumferenceJ f Corrosion Evident • Fouling EvidentD General Description of Damage 1 U&P.&

D Near TubesheetD Fatigue

• Normal to Flow

LPAKt/JC



Any Unusual Occurrence Observed Prior to Vibration as a Consequence ofO Start-up O Plant-Upset D Shutdown

Describe 1UCt.£feF0



A OF

DOE/ANL/HTRl HEAT EXCHANGER TUBE VIBRATION DATA FORM Page I






Assigned

Case No.109

Summary

This 53-in. diameter by 40-ft long CEM TEMA style heat exchangeris one of two in series that share a common shell. There isnatural gas with glycol to prevent hydration on the tube side.Between exchangers the tubeside flow passes through an openshell section about 4 ft long before entering the tubes of thedownstream exchanger. The shellside fluid is natural gasflowing counter current and piped externally between shells.The bundle has double-segmented baffles and is flat on top toa depth of 8-1/2 in. A round impingement plate the same diameteras the inlet nozzle ID is 8-1/2 in. below the nozzle. A uniquefeature is a flat plate seal welded to the shell to block shell-side flow bypassing at the top of the bundle. The maximum spanlengths are less than the TEMA Standards maximum lengths for3/4-in. carbon steel tubes.

No tube vibration has been noted in this unit even when operatedat greater than 20 percent over the designed shellside flow rate.For this case, there are construction drawings and a short fieldreport of the operating history of the exchanger train.

2-35


Type Bf TEMA ExchangerO Special Exchanger

Designation(TVcrrih*)

CEM

AssignedCane No.

Shell Orientation

109

jBLHorizontalO Vertical


£3Inside Diameter, mm ( i n . ) _ _Wall Thickness,«sk(in.)_'«Z£Inlet Nozzle I D , « n n . ( i n . ) _ 2 0

Material

7 OOutlet Nozzle ID, mm (in.)

Impingement Protection D No10 m. GO %Y

Annular Distributor 0 N o QYesOpen Cut Aremmt* (in.2)

Nozzle-to-First Tube Row Distance,«i»(in.)_


Type D Segmental; XDouble-Segmental D Disc/Doughnut

D Triple-Segmental; D No-Tubes-in-WindowBaffle Cut, % Shell Diameter 3 0 - 1Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle D Perpendicular J8 Parallel D45°Central Baffles D Perpendicular JtfParallel D45°

Baffle Thickness, BMH-(in) J2ii?> Material CSDiametral Clearances Shell-to-baffle ,-m« (in) O.'T.?!?

Tube-to-baffle mw (in.) Q.PlSfcBundle-to-shell, •n«H-(in.)

Number of Baffles Along Length of Shell ': L 5Baffle Spacing, mm(in.)__Central IG.S

Inlet _ 3 2 - Z i _ Outlet H-7b

Unsupported Tube Span Lengths, owa (in.)Longest JaUS. Inlet JjZiZSOutlet (x

Outside Diameter,<mm (in.) __fii .Wall Thickness, «»m-(in) 0.06? Material C.STube Lengths

Straight Tube, Inside Tubesheets,U-Tube, Tubesheet to Bend Tangent,'

Tube Pitch, mm (in) <-0QLayout (Please Circle)

(in.)

Flow 30?

No. of Tubes _HlQ__ No. of Tube;First Tubepass ^Countercunent O CocurrentTube-to-Tubesheet Joint

• Welded a Roller Expanded • OtherIfU-Tube

Maximum Bend Radius, mm-(in.) ^Bend Orientation Relative to Axis of Shellside Inlet NozzleD Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Finc/m (Fins/in.) Fin Material —Diameter,-w«f (in.), Root — Over Fin<

If Enhanced Surface Tubes r =

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing in tubeside and she) I side nozzles.Indicate inlet nozzles with an arrow.

tOF

Tu)O . .. . .Indicate top of exchanger as mounted


Show shellside inlet nozzl* location, tuffr* cut



PROCESS CONDITIONS

Pate 3

AssignedCaseNo._J09_

Flow Rate, kg/s (103lb/hr)

Inlet Temperature, e ^ F )

Outlet Temperature, e-(F)

Inlet Pressure,fcife-(psia) Absolute

Measured AP.Jsfa(psi)



Vibration Observed


Tubeside

-5

3\.o\.o

Shellside

SSH- 3 O

111,01,0

Jj'No DYes


Tubeade ShdUde

a No DYes



Fluid Name

Reference Temperature -fi(F)

Tubeside

NATURAL £,qs+ GL^COL.

GS

Shellside

MATURAC GAS

HeLiquid Properties at Reference

Temperatures





^^




Viscosity,-mPa«9. (cP)

Thermal Conductivity, W/wC (Btu/hr ft F)

Heat Capacity, kJ/kg-O (Btu/lb F)

Fluid Molecular Weight, Vg/rnol Ob/mole)

7>AO

7f Boiling or Condensing

Latent Heat, W/kg (Btu/lb) j |

2-37


NO


AsagMd

Cafe No. . 109

When Vibration Present, Shellside Flow Rate, kg/s (103 lb/hr)









* Please describe how v«

Vibration Caused by Ex

Damage Noted •

aType •

aWear D

D•a

Exchanger Operat

i

«

•

TUBE BUNDLE DAMA

lo

te

Nc

Ye

Ti

Tii

OrAlCoGe

io

•

>

Gl

-

cities were calculated or estimated.

rnal Sources DNo DYes

Source Frequency, Hz

D Machinery

D Cavitation

:s Complete sketch at bottom of page indicatii

be-to-Tube Impact D Cutting at Baffle

be-to-Shell Impact O Tubesheet Joint Leaking

le Side of Tubes Only D Parallel to FlowAround Tube Circumference

rrosion Evident D Fouling Evident

ppr^l JV":rppt'"n nf Dnmagp

D Piping

D Pulsating Flow

ig location in bundle

D Near Tubesheet

D Fatigue

D Normal to Flow

n History

How Long on Stream Before Dama

Any Unusual Occurrence Observed

D Start-up DPlant-l

Tk>«rihr

M> ncrwrri-At

Prior to Vibration as a Consequence of

Jpset D Shutdown


ESKETCH

n

1 i$VLJ

2-38

• o

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM Page I

i To protect the identity of the organization submitting this case, HTRI has





Assigned

Case No.110

Summary

This 45-in. diameter by 40-ft long CEM TEMA style heat exchangeris in refinery service. The tubeside fluid is cooling towerwater while the shellside fluid is an olefin-isooctane mixturewith hydrofluoric acid. Indications are that there was a loudnoise coming from the exchanger at start-up before the tubesidefluid was brought on stream. Tubes that failed were those withina few rows of the baffle tips of the double-segmental baffles.The breaks were at baffles near the center of the tube length.Metallurgical analysis indicates corrosion fatigue that wasprobably initiated by flow-induced vibration. The exchangerbundle was replaced with a new one with 18 instead of 12 bafflesand no further vibration was noted (See Case 111).

For this case, there are partial construction drawings, anindication of the specific tubes that failed, and a metallurgicalreport on the failed tubes.

2-39


AssignedCaie No. JJ°

Type J? TEMA ExchangerD Special Exchanger

Designation.(Describe)—

C.FN Shell Orientation ^HorizontalO Vertical


Inside Diameter, mm (in.)_Wall Thickness, sum (in.)Inlet Nozzle ID,*u»(in.)_Outlet Nozzle ID,«m»(in.).

Impingement Protection(Describe)

Material.

No O Yes

Annular Distributor ITNoOpen Cut Area mm* (in.z)

Q Yes

Nozzle-to-First Tube Row Distance, mm (in.) \.


Type D Segmental; ^Double-Segmental D Disc/Doughnut

D Triple-Segmental; Q No-Tubes-in-WindowBaffle Cut, % Shell Diameter ihJt.Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle D Perpendicular 55 Parallel D45°Central Baffles D Perpendicular jfParallel O45°

Baffle Thickness, BHn-(in.)-&ife£?Material C6Diametral Clearances Shell-to-baffle, +-•* ( in . )_QA2i

Tube-to-baffle «w«-(in.)_Bundle-to-shell, « m (in ) 1. 111>

Number of Baffles Along Length of Shell 1"?Baffle Spacing, mm-(in.) Central _

Inlet VSfj Outlet _

Unsupported Tube Span Lengths,-m«-(in.)longest lOM Inlet "?0.Y Outlet 7(?V

,mm(in.) LH.Outside Diameter,mm (in.).Wall Thickness, *m*i (in) O . ^ V MaterialTube Lengths

Straight Tube, Inside Tubesheets.Jtmi ( in)U-Tube, Tubesheet to Bend Tangent, mm (in.) ~~

Tube Pitch, «mr(ui.) l m ^Layout (Please Circle)

Flow

No. of Tubes. No. of Tube;First Tubepass B Countercurrent D CocunentTube-to-Tubesheet Joint

^Welded JSRolIer Expanded D O t h e r —IfU-Tube

Maximum Bend Radius, mm (in)Bend Orientation Relative to Axis of Shellside Inlet NozzleD Perpendicular • ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Km/m (Fins/in.) — Fin Material —Diameter, mm (wr), Root Over Fin* **~

If Enhanced Surface Tubes ZZ

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing In tubvslde and shell side nozzles-Indicate inlet nozzles with an arrow.

t Indicate top of exchanger at mounted


Show shellsKK Inlet nozzle location, baffle cutorientation, and Implnfemwit devices.


Assigned

" 0

PROCESS CONDITIONS

Flow Rate, kg/s(103lb/hr)Inlet Temperature,-e-(F)Outlet Temperature,* (F)Inlet Pressure,-W>a (psia) AbsoluteMeasured AP, kP» (psi)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed



Fluid NameReference Temperature "©'(F)


Tubeade

O

0

Shellade

1,1,00

°iOloo—O0

• No HYes

Tubeside

WATGE_

1


Tubeade SkeDade

• No DYes

I50&UTAWFSheUside

HVO<?OP< UoCic AciO0(3


Density, kg/m3 (lb/ft3)Viscosity ,-mP*«*-(cP)Thennal Conductivity, Wjm*G (Btu/m ft F)Heat Capacity, KJ/leg-G (Btu/m ft F)

O.feS*

Vapor or Gas Properties itReference Temperatures

Density, kg/m3 Ob/ft3)Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/hr ft F)Heat Capacity, kJ/kg-C (Btu/lb F)Fluid Molecular Weight, kg/mol Qb/mole)

\\

\

If Boiling or Condensing ^y \ y^ \ _Latent Heat, kJ/kg (Btu/lb)

2-41


Case N o . . 110


When Vibration Present, Shellside How Rate.-kftl* (103 lb/hr) 1100If Known, Crossflow Velocity at baffle t\p,mfs(ft/sec)*


Velocity Through Window in Baffle, mfr (ft/sec)*

Inlet Nozzle Velocity, m/f (ft/sec)*





Vibration Caused by External Sources DYes


D Machinery

• Cavitation

. rpm.

O Piping

D Pulsating Flow

Damage Noted

Type

Wear

DNoComplete sketch at bottom of page indicating location in bundle



Shutting at BaffleO Tubesheet Joint Leaking

D One Side of Tubes Only D Parallel to FlowD All Around Tube Circumference^ Corrosion Evident D Fouling EvidentD General Description of Damage 1H

O Near Tubesheet

O Fatigue

D Normal to Flow

tPSAtJO HO




O Start-up • Plant-Upset • Shutdown

Describe

If Vibration Remedy Applied, Describe and Indicate Results:U(TH IB E>APCtP<. Aid PQgTHfc VQOll


2-42





This is a replacement for the original page 1 that provides space fox


Assigned

Case No. Ill

Summary

This 45-in. diameter by 40-ft long CEM TEMA style heat exchangeris the same shell as for Case 110 with a replacement bundle. Theseare 18 double-segmental baffles instead of the original 12. Theservice and the fluids are the same. This exchanger resulted ina higher shellside pressure drop; however, added pump capacitywas available. The exchanger has operated for several yearswithout any vibration problems.

The information is limited to that included on the data form.

• • i _ .

2-43


AssignedCue No. . I l l

Type fB.TEMAExchanger

D Special Exchanger

Designation.

(Describe)

Shell Orientation tf Horizontal

• Vertical


Inside Diameter, mm (in.) Ub

Wall Thickness,mm (in.) Material-

Inlet Nozzle ID, mm ( in) 1H

Outlet Nozzle ID, mm (in) lH

Impingement Protection ^.No D Yes(Describe) *

Annular Distributor JSNoOpen Cut Area aim2 (in.2)

DYes

Nozzle-to-First Tube Row Distance, mm (in.).


Type D Segmental; ^Double-Segmenta! D Disc/Doughnut

O Triple-Segmental; D No-Tubes-in-Window

Baffle Cut, % Shell Diameter

Cut Orientation Relative to Axis of Inlet NozzleInlet Baffle • Perpendicular # Parallel D45°Central Baffles • Perpendicular ^Parallel 045°

Baffle Thickness, mm (in ) 0 '6£?Materia1Diametral Clearances She]J-to-baffie,»wB-(in.)_

Tube-to-baffle mm (in.).Bundle-to-shell, mm- (in) | .t

Number of Baffles Along Length of ShellBaffle Spacing,•mmîn.) Central

Inlet IH'iy Outlet _ J

Unsupported Tube Span Lengths, mm (in.).longest SO iniet W\y Outlet J

-L©_Outside Diameter,-inm(in.)_Wall Thickness, m » (in) O.tW MaterialTube Lengths

Straight Tube, Inside Tubesheets, mm (in)U-Tube, Tubesheet to Bend Tangent, mm-On.) ~

Tube Pitch, jam.(in.) (jZb

. No.ofTubep


Flow

No. of Tubes.

First Tubepass KCountercurrent D Cocurrent


JfWelded ^RoUer Expanded D Other

IfU-Tube

Maximum Bend Radius, twin (in.) "^.


D Perpendicular D Parallel —If Bend Supported, Describe in Comments Below

If Finned Tubesfttw/fn (Fins/in.) —' Fin Material " ~Diameter, mot (in.), Root Over Fins "~

If Enhanced Surface Tubes '

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing in tubeslde and shellslde nozzles.Indicate inlet nozzles with an arrow.

IFT

Fixed Tubesheet

tC=> indicate lop of exchanger as mounted

by filling in appropriate arrow. 2-44

Show shellslde Inlet nozzle location, battle cutorientation, and Impingement devices.


AssignedCase No.. 111

PROCESS CONDITIONS

Flow Rate, leg's (103lb/hr)Inlet Temperature,-e-(F)Outlet Temperature,*<F)Inlet Pressure, Wfr(psia) AbsoluteMeasured AP, W» (psi)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed


TubewJe

O

o

ShelUde

<\±<*0

loo—O

oXNo a Yes


Tubaide SheUade

O No DYes



Fluid NameReference Temperature *<F)

Tubeside

WATUk

Shdlside


Density, fcg/m3 (lb/ft3)Viscosity,-mft»-s (cP)Thermal Conductivity, WfnrG (Btu/m ft F)Heat Capacity,k#fcg-€- (Btu/m ft F)


Density, kg/m3 (lb/ft3)Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/hr ft F)Heat Capacity, kJ/kg-C (Btu/lb F)Fluid Molecular Weight, kg/mol Ob/mole)

If Boiling or Condensing

" \ ^

> \ »

Xx~

^X

/ XX N

x^

yX

yXX

/ X/ \Latent Heat, kJ/kg (Btu/lb) \^X \ X * X ^

2-45


AMgnedCue No. . 111


When Vibration Present, SheUside Flow Rate, kg/s (103 lb/hr)










Vibration Caused by External Sources O No D Yes


O Machinery

D Cavitation

. rpm.

D Piping

D Pulsating Flow

Damage Noted

Type

Wear

D N o

DYes Complete sketch at bottom of page indicating location in bundle



• Cutting at Baffle

• Tubcsheet Joint Leaking

Q One Side of Tubes Only D Parallel to FlowO All Around Tube CircumferenceD Corrosion Evident D Fouling EvidentD General Description of Damage

D Near Tubesheet

D Fatigue

O Normal to Flow




O Start-up Q Plant-Upset D Shutdown

Describe



n

LJ

2-46


To protect the identity of the organization submitting this case, HTRI hasassigned a case number. Additionally the data on pages 2,3, and 4 have beenreviewed to ensure that they do not include any propietary information.This is a replacement for the original page 1 that provides space foradditional comments, drawings, photographs, etc.


Summary

This 43-in. diameter by 19-ft long AJS TEMA style heat exchangerhas an annular distribution at the center inlet with a series ofslots to direct half of the shellside flow of air to each of thetwo ends of the exchanger. Cooling tower water flowed in thetube side. The bundle has segmental baffles with relativelyshort unsupported span lengths for 3/4-in. admiralty tubes. Thetube field is arranged in an inline layout with a pitch—to-diameter ratio of 1.33. The indication is that this exchangerhad "frequent tube leaks." Unfortunately, there is no indicationas to where the leaks occurred. Tube vibration is given as theprobable cause.

For this case, there are partial construction drawings, a fieldinspection report, and the exchanger specification sheet.

2-47

DOE/ANL/HTR] HEAT EXCHANGER TUBE VIBRATION DATA FORM Pige2

AssignedCue No.. 112

JType J^TEMA Exchanger Designation _ _ A 3 I £ L .

D Special Exchanger (Describe)Shell Orientation • Horizontal

O Vertical


Inside Diameter,Wall Thickness,Inlet Nozzle ID,

(in.) Material.

LfaOutlet Nozzle I D , M » ( i n . ) _ _ L 2 _ _

lmpingement Protection JfNo • Yes(Describe) I T !

Annular Distributor D NoOpen Cut Area mm? (in.2)

Nozzle-to-First Tube Row Distance, aua.(in.) I < k7 S


Type J^Segmental; • Double-Segmental D Disc/Doughnut

D Triple-Segmental; D No-Tubes-in-WindowBaffle Cut, % Shell DiameterCut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle O Perpendicular BTParallel D45°Central Baffles • Perpendicular KParallel O45°

Baffle Thickness, wm (in.)_QLiiz_Material OSDiametral Clearances She)l-to-haffle,<w«(in.) 0 . 2 S

Tube-to-baffle miw(in ) O.OlSfcBundle-to-shell, imn-(in.)

Number of Baffles Along Length of Shell _BJBaffle Spacing,•m«.(in.) Central _

Inlet 13> Outlet 7.1.1 ^

Unsupported Tube Span Lengths,Longest_yîL_ InJet

Outside Diameter, K )Wall Thickness, «*w(in) 0.065" Material APfilBAL.TV'Tube Lengths

Straight Tube, Inside Tubesheets, i—în ) "2^7* Û-Tube, Tubesheet to Bend Tangent, mm-(in.)

Tube Pitch, wai^n.) 1 ' ° ^Layout (Please Circle)

Flow

No. of TubesFirst Tubepass f] Countercurrent fiTCocurrentTube-to-Tubesheet Joint

O Welded B( Roller Expanded D OtherIfU-Tube

Maximum Bend Radius,-mm(in)Bend Orientation Relative to Axis of Shellside Inlet NozzleO Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

¥imfm (Fins/in.) Fin MaterialDiameter, Bw»(in.)i Root • ^ Over Fin*

If Enhanced Surface Tubes !r^

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing tn tubeside and shellside nozzles.Indicate inlet nozzles with an arrow.

Fixed TubeshiL - cewfe

X_L

C = •=£>Indicate top of exchanger as mountedby filling in appropriate arrow. 2-48

Show snelliid* Inlet nozzle location, baflle cutorientation, and impingement devices.


AssignedC«eNo._JJ2_

PROCESS CONDITIONS

Flow Rate, fceM103lb/hr)Inlet Temperature,>e(F)

Outlet Temperature, e ( F )

Inlet Pressure, left (psia) Absolute

Measured AP,tft(psi)Inlet Weight Fraction Vapor

Outlet Weight Fraction VaporVibration Observed


Tubeade

°lo

ho0

ShdUde

USi.sr

D No KYes

Reference Conditwn t

Tubaide SkdWde

DNo D Yes



Fluid Name

Reference Temperature €-(F)

Tubeside

UA1GZ

Shdlside

Ate.1


Temperatures


Viscosity, mPa*s (cP)Thermal Conductivity, W/m-C (Btu/m ft F)Heat Capacity, kJ/kg'C (Btu/m ft F) _̂ "

^ — • "

^ — "




Viscosity, mPa-s (cP)Thermal Conductivity, W/m-C (Btu/hr ft F)


Fluid Molecular Weight, kg/mol Ob/mole)If Boiling or Condensing

Latent Heat, kJ/kg (Btu/lb)

\

X M —

2 - 4 9


Asafened

Case No. . 112


When Vibration Present, Shellside Flow Rate, Itgfc (103 lb/hr)

If Knov^n, Crossflow Velocity at baffle tip, mis (ft/sec)*

Crossflow Velocity at centerline, n / s (ft/sec)*

Velocity Through Window in Baffle, mfc (ft/sec)*

Inlet Nozzle Velocity,nth (ft/sec)*

Outlet Nozzle Velocity, n^» (ft/sec)'





Vibration Caused by External Sources DYes


O Machinery

O Captation

. rpm.

O Piping

• Pulsating Flow

Damage Noted

Type

DNoJ^Yes (

D Tube-to-Tube

D Tube-to-Shell

temple

Impact

Impact

Ccmplete sketch at bottom of page indicating location in bundle

Wear

• Cutting at Baffle

D Tubesheet Joint Leaking

O One Side of Tubes Only D Parallel to FlowO All Around Tube CircumferenceD Corrosion Evident D Fouling EvidentD General Description of Damage

D Near Tubeshset

D Fatigue

O Normal to Flow




• Start-up D Plant-Upset D Shutdown

Describe



2-50

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM hgel


assigned a case number. Additionally the data on pages 2, 3, and 4 have been

reviewed to ensure that they do not include any propielary information.



Assigned

Case No. 113

Summary

This 17-in. diameter by 16-ft long AEU TEMA style heat exchangerhas cooling water flowing inside the two tube passes formed bythe U-tubes. On the shell side a hydrocarbon designated"Atmospheric Top Pumparound" flows through a bundle with seg-mental baffles with very little overlap so the flow is mostlyparallel to the tubes. Originally admiralty tubes were usedand these suffered damage. The inspection report indicatesevidence of "fretting corrosion with numerous penetrationsunder baffles." The indication is that there was a combinedeffect of vibration and corrosion. The tubes--that failed werenear the longitudinal baffle passlane and at the baffle plates.The cutting action resulted in the tubes being worn throughon one side, but the specific orientation is not noted.

For this case, there are in addition to the data form, aninspection report, transmittal letter, and an indication ofthe remedial action taken. The bundle was retubed with 430 alloystainless steel except for the bottom row of fin tubes whichwere with titanium. No further problems have been indicated.

2-51

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM Page 2

Assfeaed

Caw No. 113

Type KTEMA Exchanger

D Special ExchangerDesignation..(Describe)—

Shell Orientation ^Horizontal

D Vertical

SHELL GEOMETRY (Complete Sketch Below) TUBEGEOMETRY

Inside Diameter, <a*m (in.)_Wall Thickness, MMt-(in.)J?!Inlet Nozzle ID, mm ( in . )_Outlet Nozzle ID, mm (in.).

Impingement Protection

(Describe)

n.isMaterial.

DYes

Annular Distributor PtNo DYes

Open Cut Area mm2 (in.2) Z^.

Nozzle-to-First Tube Row Distance, «M»-(in.) 2 « VT, 7 5


Type KSegmental; O Double-Segmental • Disc/Doughnut

D Triple-Segmental; • No-Tubes-in-Window

Baffle Cut, % Shell Diameter W3.S


Inlet Baffle D Perpendicular JJTParallel D45°

Central Baffles O Perpendicular JJParallel D45°

Baffle Thickness, mm ( i n . ) £ i l £ . Material

O.\%1Diametral Clearances Shell-to-baffle,m»-(in.).

Tube-to-baffle•»»« (in.)_

Bundle-to-shell, mm (in.) KjQ

Number of Baffles Along Length of Shell »Baffle Spacing,*!* (in.) Central 1~l

Inlet Jl Outlet 11

Unsupported Tube Span Lengths, mm (in.)Longest 5"V Inlet 5H Outlet 5 V

Outside Diamgtrr mnr(in) *T.i>Q

WaU Thickness, mm (in ) 0.O6S

Tube LengthsStraight Tube, Inside Tubesheets, mm ( in)U-Tube, Tubesheet to Bend Tangent,mm (in.)

Tube P i i rh ,^»( in ) I '00


Flow

No. of Tubes

First Tubepass O CountercunentTube-to-Tubesheet Joint

D Welded M Roller Expanded O OtherIfU-Tube

Maximum Bend Radius, mm (in )

O Cocunent

Bend Orientation Relative to Axis of Sbellside Inlet Nozzle• Perpendicular ^Parallel

If Bend Supported, Describe in Comments BelowIf Finned Tubes

(Fins/in.) Fin MaterialDiameter, mm (in.), Root Over Fins.

If Enhanced Surface Tubes TT^T

(Describe) ZT=

DETUNING BAFFLE

If Detuning Baffle Used to Control'Acoustic


COMMENTS AND SKETCH

Complete sketches by drawing In tubeside and sheUslde nozzles.Indicate inlet nozzles with an arrow.

Fixed Tubeiheet DIndicate top of exchanger as mountedby filling In appropriate arrow. 2-52

Show shellslde Inlet nozzle location, baffle cutorientation, and impingement devices.


AssignedC«e No. " 3

PROCESS CONDITIONS

Flow Rate, Jfg/s (203lb/hr)Inlet Temperature, €-(F)Outlet Temperature,€-(F)Inlet Pressure, k£a-(psia) AbsoluteMeasured AP,Jt£a-(psi)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed


Tubeade

"TOion

0O

ShdUde

life

OO

O No Xfres

Reference Conditioa B

Tubeade ShdUde

a No QYes



Fluid NameReference Temperature -C\F)


Density, *g /» 3 (Ib/ft3)Viscosity ,-mPa^s (cP)Thermal Conductivity, W/m-e (Btu/m ft F)Heat Capacity,-W/Itg^ (Btu/m ft F)

Tubeside Shdlade

1-bH I7G

-

43.IV0.11

W.SV0.11


Density, kg/m3 Ob/ft3)Viscosity, mPa*s (cP)Thermal Conductivity, W/m-C (Btu/hr ft F)Heat Capacity, kJ/kg-C (Btu/lb F)Fluid Molecular Weight, kg/mol Ob/mole)

\y /

y SS"

\

y /

y /yS

/ \If Boiling or Condensing / > ^ yS " S ^

Latent Heat, kJ/kg (Btu/lb) y \i/' \

r

2-53


''aje No.. 113


When Vibration Present, Shellside Flow Rate, lb/hr)

If Known, Crossflow Velocity at baffle tip<m/t<ft/sec)'Crossflow Velocity at centerline,-w£ (ft/sec)*

Velocity Through Window in Baffle, «& (ft/sec)*Inlet Nozzle Velocity,j»/t. (ft/sec)*

Outlet Nozzle Velocity,«/s (ft/sec)*




Vibration Caused by External Sources OYesSource Frequency, Hz.

n MachineryD Cavilation

• PipingD Pulsating Flow

Damage Noted

Type

Wear


D Tube-to-Tube ImpactO Tube-to-Shell Impact

BaffleD Tubesheet Joint Leaking

D Near Tubesheet• Fatigue

Q Normal to Flowit One Side of Tubes Only Q Parallel to FlowD All Around Tube CircumferenceD Corrosion Evident • Fouling EvidentD Genera) Description of Damage TuJO Tt/fcCf; WOR A) TtiRfl(J6M Ok) OkiE

AiExchanger Operation History



• Start-up Q Plant-Upset O Shutdown

Describe



2-54




reviewed to ensure that they do not include any propietaiy information.



Assigned

Case No. 114

Summary

This 56-in. diameter by 50-ft long AEL TEMA style heat exchangerhas a hydrocarbon gas stream on both the shell side and the tubeside. The "lean gas" is heated on the shell side where the bundlehas 19 "double double-segmental" baffles. See sketch below.The "rich gas" is cooled on the tube side in a single tube pass.There was no impingement device under the shellside inlet nozzle.Tubes failed in "top three rows under shell inlet nozzle."

For this case, in addition to the data form is a description ofthe process conditions and geometry including the sketchreproduced below.

•- I I . I "

2-55

DOE/ANL/HTRI HEAT EXCHANGER TUBE VIBRATION DATA FORM fife 2

Type S. TEMA Exchanger• Special Exchanger

Designation(Describe)

AELCase No.

Shell OrientationNOT filt/Gd

114

• HorizontalD Vertical


lO

Inside Diameter,«n*(in.)Wai! Thickness, nmt(in.)Inlet Nozzle ID,«k* (in)Outlet Nozzle ID,«»(in.)

Impingement Protection KNo(Describe) ITZ

Material

2iiO Yes

Annular Distributor ^ N o DYesOpen Cut ATeaiwu? (in.2) ~

Nozzle-to-First Tube Row Distance, iwti (in.) V. I


Type OSeemental; BDouble-Segmental • Disc/Doughnut

D Triplc-Segmental; O No-Tubes-in-WindowBaffle Cut, % Shell Diameter *3OCut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle DPerpendicular B Parallel D45°Central Baffles G Perpendicular JeTParallel D45°

Baffle Thickness, mm (in.)SLbkl- MaterialDiametral Clearances Shell-to-baffle, mm (in.) 0 . 2 65

Tube-to-baffle w«-(in) O.OIgfcBundle-to-shell, imw(in ) O.

Number of Baffles Along Length of Shell L9Baffle Spacing, mm (in.) Central *%rO

Inlet \9, Outlet 17

Unsupported Tube Span Lengths,im* (in.).Longest ̂ hSl— Inlet _ S 2 _ Outlet _

Outside Diameter, mm (in) Q.7.C<9Wall Thickness, rnn (in.) 0iOg3 Material.Tube Lengths

SHbStraight Tube, Inside Tubesheets.mn (in.).U-Tube, Tubesheet to Bend Tangent, mm (in.) —

Tube Pitch, mm-(in.)Layout (Please Circle)

Flow

No.ofTubes_2fli£L No. ofTubepassesFirst Tubepass JlCountercunent a CocurrentTube-to-Tubesheet Joint

D Welded a Roller Expanded n n t h w NoTIfU-Tube

Maximum Bend BaHim, ••••.(in )

Bend Orientation Relative to Axis of Shellside Inlet Nozzle• Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

Fim/m (Fins/in.) ~~ Fin Material "~Diameter, H*nr(in.), Root ~" Over Fin^ -~

If Enhanced Surface Tubes ~ "

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing in tubeslde and shellside nozzles.


Fixed Tubeshcet I

1 I ' ! 'JL -

i_ru:t

by filling In i 2-56

Snow shells id* Inlet nozzle location, b j t i t * cut



AssignedH 4

PROCESS CONDITIONS

Flow Rate, fcg£(103lb/hr)Inlet Temperature, €-(F)

Outlet Temperature, € (F)

Inlet Pressure,W»(psia) Absolute

Measured AP, kPe-(psi)



Vibration Observed


Tubeade

bll.l

- \ h

1.01.0

Shellnde

HS9.1

1.01.(9

O No fcYes


Tubeade ShdUde

D No a Yes



Fluid Name

Reference Temperature •fr(F)

Tubeside

RICH GA'b

Shdlside

LE^M GAS

- \9.h 1 2OLiquid Properties at Reference

Temperatures



Thermal Conductivity, W/nvC (Btu/m ft F)

Heat Capacity, kJ/kg-C (Btu/m ft F)^



Density, kgA»3 (lb/ft3)

Viscosity, -mftrfl (cP)Thermal Conductivity, W/«n-€ (Btii/hr fl F)

Heat Capacity, kJ/kg-C- (Btu/lb F)

Fluid Molecular Weight, feg/nwKIb/mole)

O.OM0.0\%W

—

0.0120.010b

16.67

o,o\d%o.o\n%—

O.OIZO

O.02O7O.&Otf

n.«//If Boiling or Condensing

Latent Heat, W#tg<Btu/lb) - [ • —

2-57

OOE/ANL/HTR] HEAT EXCHANGER TUBE VIBRATION DATA FORM

Case No . . 114


When Vibration Present, Shellside Flow Rate,fc^»(103 lb/hr)

If Known, Crossflow Velocity at baffle tip,«wj<*(ft/sec)*

Crossflow Velocity at centerlinc,-«»/t (ft/sec)*

Velocity Through Window in Baffle, mife(ft/sec)*

Inlet Nozzle Velocity,«^6 (ft/sec)*

Outlet Nozzle Velocity , •»£ (ft/sec)*




Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources JStfMo a Yes


D Machinery

D Cavitation

. rpm.D Piping

D Pulsating Flow

Damage Noted

Type

Wear


O Tube-to-Tube Impact

D Tube-to-Sliell Impact

D Cutting at Baffle

• Tubcshect Joint Leaking

O One Side of Tubes Only D Parallel to Flow

D All Around Tube Circumference

D Corrosion Evident D Fouling Evident

) ? General Description of Damage

JEf Near Tubesheet

O Fatigue

O Normal to Flow

TOP 3 P0GJ5





Describe



2-58







Assigned

Case No.115

Summary

This 69-in. diameter by 20-ft long BJS TEMA style heat exchangeris used as a process gas cooler. Shellside flow entered thesingle 42-in. nozzle at the center of the exchanger and wasdirected to the two ends by a solid flow divider plate. A portionof the nozzle was blanked off to prevent by passing and reducedthe flow area to the equivalent of a 40.6-in. diameter nozzle.There were five crosspasses on each end with segmental baffles.The outlet nozzles were 26 in. diameter and mated matching 26-in.diameter nozzles on a vessel that acted as a collecting header tocombine the flow into a 42 in. diameter outlet line. See sketchbelow. It should be noted that the tubefield layout was inline.There has not been any tube damage reported. However, there isan extremely loud noise. The noise was greatest at the fixedtubesheet at the top of the shell and at the bottom of the shellnear the floating head. The shellside pressure drop was pulsingbetween 2 to 4 psi. It is not clear that the noise was flow-induced inside the shell and not being generated by an outsidesource.

For this case, in addition to the data form, there are completeconstruction drawings of the exchanger (not the collecting header),a description of noise observations, and several sketches.

2-59


AssignedCase No. .

Pafe2

115

Type J* TEMA Exchanger Designation.• Special Exchanger (Describe)

R.tS Shell Orientation SOiorizontaJO Vertical


Inside Diameter, iWall Thickness, •Inlet Nozzle ID, «

Material _ £ £ _t On.).» ( i n . ) _ y i _ BtMiK£.O in HO.k

Outlet Nozzle ID,maj-(in.)__-2&

Impingement Protection jSOô(Describe)

D Yes

Annular DistributorOpen Cut Area mm2 (in.2)

Nozzle-to-First Tube Row Distance,

OYes


Type HSegmental; D Double-Segmental D Disc/Doughnut

D Triple-Segmental; • No-Tubes-in-WindowBaffle Cut, % Shell nianwur H S~Cut Orientation Relative to Axis of Inlet Nozzle

Inlet Baffle B Perpendicular • Parallel D45°Central Baffles EfPerpendicular O Parallel O45°

Baffle Thickness, m» (in.) _&j_£fi Material C SDiametral Clearances Shell-to-baffle, mm (in.)

Tube-to-baffle mm (in.)Bundle-to-shell, mm (in.)

Number of Baffles Along Length of Shell 9Baffle Spacing,•»«• (in.) Central )R

Inlet lO.lS Outlet i

Unsupported Tube Span Lengths, «w» (in.).Longest _£5Lll2jnlet T& Outlet _

Outside Diameter, mm (in.) 6-Wall Thickness, «wi (in ) 0.0S3Tube lengths

Straight Tube, Inside Tubeslieets. (in.)U-Tube, Tubcsheet to Bend Tangenl.-mm (in.)

Tube Pitch,«&(in.) !•?$


Flow

lotsNo. of Tubes No. of TubepaisesFirst Tubepass JJCountercurrent (giCocurrentTubeto-Tubesheet Joint

Q Welded JSRoUer Expanded D OtherIfU-Tube

Maximum Bend Radius,-»nm(in.)__mBend Orientation Relative to Axis of Shellside Inlet NozzleD Perpendicular D ParallelIf Bend Supported, Describe in Comments BelowIf Finned Tubes

K M M (Fins/in.) *~ Fin MaterialDiameter,4w«-(in.), Root Over Fins "**

If Enhanced Surface Tubes I!Z

(Describe).

DETUNING BAFFLE



COMMENTS AND SKETCH

Complete sketches by drawing In tubeside and shellside nozzles.Indicate inlet noz2les with an arrow.

Indicate top of exchanger as mountedby filling In appropriate arrow. 2-60

Show shellside Inlet nozzle location, baffle cut



AssignedC m N o " 5

PROCESS CONDITIONS

Row Rate, kpis (103lb/hr)Inlet Temperature, e (F)Outlet Temperature,€-(F)Inlet Pressure, •#» (psia) AbsoluteMeasured AP.fcfeKpsi)Inlet Weight Fraction VaporOutlet Weight Fraction VaporVibration Observed


Tubeade

2 7

9ft-O0

Sbdlade

372

—1.01.0

DNo MYes


Tubeade Shdlade

O No OYes

* CALCULA'eOFLUID PHYSICAL PROPERTIES


Fluid NameReference Temperature -e-(F)

Tubeside

WAT£R

SheUade

Ptfoces-s &AS


Density, itgfm3 (lb/ft3)Viscosity, u»P»*s (cP)Thermal Conductivity, W/nr€ (Btu/m ft F)Heat Capacity, U/kg-€-(Btu/m ft F)


Density, kg/m-3 (lb/ft3)Viscosity, jnPa->&- (cP)Thermal Conductivity, Wyn**G-(Btu/hr ft F)Heat Capacity, lt#kg*G-(Btu/lb F)Fluid Molecular Weight, kg/swl Ob/mole)

If Boiling or CondensingLatent Heat, W/*e(Btu/lb) 1

. 1

y S/

0.00^0.03HC0.333O

2.2.9*1

2 - 6 1


AsagaedCue No.. 115


When Vibration Present, Sheilside Flow Rate,4tg/t(103 lb/hr) JLLLIf Known, Crossflow Velocity at baffle tip, m^(ft/sec)*

Crossflow Velocity at centerline, mfs (ft/sec)*Velocity Through Window in Baffle,-**/* (ft/sec)*

Inlet Nozzle Velocity, mft (ft/sec)*Outlet Nozzle Velocity ,-w/s (ft/sec)*

Measured Natural Frequency, HzMeasured Acoustic Frequencies, HzNoise Sound Level, db

• Please describe how velocities were calculated or estimated.

Vibration Caused by External Sources DNo DYes ]H Ho&TSource Frequency, Hz

O Machinery

D Cavitation

rpmD PipingD Pulsating Flow

Damage Noted

Type

JSl.NoQ Yes <

• Tube-to-TubeD Tube-to-ShcH

Zomple

ImpactImpact

Complete sketch at bottom of page indicating location in bundle

Wear

• Cutting at BaffleD Tubesheet loint Leaking

D One Side of Tubes Only D Parallel to Flow• All Around Tube CircumferenceD Corrosion Evident D Fouling Evident• General Description of Damage No

A? T</uic£ i?6g.f/^*J n o

D Near TubesheetO Fatigue

• Normal to Flow

~°Exchanger Operation History


Any Unusual Occurrence Observed Prior to Vibration as a Consequence of• Start-up D Plant-Upset D Shutdown

Describe



JO

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