I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q.

23 (3) 287294 (2009)

287

Vibration Analysis of Heat Exchangers of a Nitric Acid Plant

I. olji,* Lj. Matijaevi, and I. Dejanovi
Faculty of Chemical Engineering and Technology,
University of Zagreb, Savska c. 16, Zagreb, Croatia

Original scientific paper

Received: March 17, 2008
Accepted: February 13, 2009

This paper deals with an operational problem of two heat exchangers of the nitric
acid synthesis plant. Detailed calculation and vibration analysis were made and vibration
problem of the nitrous gases cooler E-111 was identified. When the vibration problem
was indicated, several steps were taken for its removal. For five different types of baffles
a study was made to determine how their number and spacing influence the cross-flow
rate of the fluid. Results showed that the vibration problem cannot be removed completely, but it can be reduced considerably with different types of baffles. Also, the analysis showed that the cooling water condenser E-114 does not have a vibration problem.
Key words:
Heat exchangers, vibration analysis, baffles, tube failure

Introduction
In this work, a detailed calculation and vibration analysis were performed for two shell-and-tube
heat exchangers of the nitric acid plant (Fig. 1).
Heat exchangers are used for cooling nitric gases
before their entry into the absorption column. It is
well known that lower temperature and higher pressure enable better absorption of nitric gases. Thus,
the absorption efficiency depends on the amount of
heat transferred through the two heat exchangers.1
In the first heat exchanger (E-111), compressed
nitric gases from the top of the whitening column
are cooled with purge gas from the top of the absorption column. In the second heat exchanger
(E-114) nitric gases are cooled with cooling water
(Fig. 2).
Practical experience has indicated that heat
exchangers have a major operational and noise
problem; therefore, a detailed vibration analysis
was made. When a vibration problem of one heat
exchanger was identified, an additional study was
made for five different types of baffles. Simulation was performed using chemical process simulation software ChemCAD i.e. its integrated module
CC-THERM, an interactive simulation tool for design and rating of the shell-and-tube heat exchangers.2
The results obtained in this work can be helpful
for engineers to design heat exchangers of the nitric
acid synthesis because the current design criteria
are based on data collected with water and air,
while the prediction of whether or not a given heat
* Corresponding

author: Ivana olji, B.Sc.Chem.E.

Faculty of Chemical Engineering and Technology, University of Zagreb, Maruliev trg 19, P.O. Box 177, HR-10000 Zagreb, Croatia
Tel: ++385-1-4597-162, Fax: ++385-1-4597-142, E-mail: [email protected]

exchanger configuration will resist vibration and

tube failure is not yet well defined.

Case study
Both
analyzed
heat
exchangers
are
shell-and-tube type designed by TEMA standards3
with single segmental baffles inside the shell. Based
on their construction, they are classified as
fixed-tubesheet heat exchangers with bonnet-type
channel covers (TEMA class C/BEM). They have
straight tubes that are secured at both ends to
tubesheets welded to the shell (Fig. 3).
The most common materials of construction
for TEMA heat exchangers are carbon and stainless
steel and their properties and composition are specified by ASTM standards.4 In most cases, all components are made of identical materials. Some heat
exchangers are constructed from dissimilar metals
and in that case extreme care in their selection is required since electrolytic attack may develop.5 Table
1 shows basic data about these two heat exchangers.
Tube bundle and baffles

A tube bundle is the most important part of a

tubular heat exchanger. Tubes are generally the
most expensive part of the exchanger and they are
most prone to corrosion. Tube sheets, baffles or
support plates, tie rods and, usually, spacers complete the bundle.5
Baffles serve two important functions:
Support the tubes during assembly and operation, helping to prevent vibration from flow-induced eddies.

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I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

F i g . 1 PFD of the nitric acid plant

F i g . 2 Observed section of the process

F i g . 3 Fixed-tubesheet heat exchanger6

I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

289

T a b l e 1 Elementary data about exchangers, E-111 and

E-114

F/kW

Nitrous gases cooler,

E-111

Cooling water
condenser, E-114

2266.3

813.9

Tube side
Compressed nitrous
gases

Compressed nitrous
gases

70 753.0

81 952.0

qi/C

43.0

80.0

qo/C

153.0

50.0

pi/MPa

0.795

0.800

Fluid
qm/kg h-1

construction
stainless steel;
stainless steel;
ASTM A 249 TP 304L ASTM A 249 TP 304L
material
Shell side
Purge gas from T-103

Cooling water

81 952.0

100 000.0

qi/C

176.0

28.0

qo/C

80.0

35.0

pi/MPa

0.800

0.450

stainless steel;
ASTM A 240 304L

carbon steel;
ASTM A 285 C

Fluid
qm/kg h-1

construction
material

Direct the shell-side fluid back and forth

across the tube bundle to provide effective velocity
and heat transfer rates.
There are several types of baffles,6 as shown
in Fig. 4. Single segmental and double segmental
baffles reduce cross-flow rate for a given baffle
spacing. The triple segmental reduce both
cross-flow and long-flow rates and are identified
as the window-cut baffles. In some special cases
no-tubes-in-window, disc-and-donut and rod baffles
are used. Rod or bar baffles have either rods or bars
extending through the lanes between the rows of
tubes. The shell-side flow is uniform and parallel to
the tubes. Stagnant areas do not exist.7
Segmental baffles do not extend edge to edge
but have a cut that allows shell-side fluid to flow to
the next baffle chamber. For most liquid applications, the cuts areas represent 20 to 25 % of the
shell diameter. For gases, where a lower pressure
drop is desirable, baffle cuts of 40 to 45 % are common. Two type of baffle cut orientation are usually
used (Fig. 5). Horizontal baffle cut is recommended
for single-phase fluid on the shell side, because this
minimizes accumulation of deposit at the bottom of
the shell and also prevents stratification. In the case
of a two-pass shell, a vertical cut is preferred for
ease of fabrication and bundle assembly.6

F i g . 4 Types of baffles6

F i g . 5 Baffle cut orientation5

Baffles must overlap at least one tube row in

order to provide adequate tube support. They are
spaced somewhat evenly throughout the tube bundle to provide even fluid velocity and pressure drop
in each baffled tube section.
Noise and vibration problems in tube bundles

Tube bundles in heat exchangers are often subject to vibration and noise problems. Vibration can
lead to wear and consequential tube failures.8 Damage is more likely to occur with gases or vapours on
the shell-side than with liquids. Flow-induced vibrations also occur with liquids, but the damage is
often limited to localized areas of relatively high
rate.
The tubes vibrate only at unique responding
frequencies called their natural frequencies. The

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I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

natural frequency of the tubes depends primarily on

their geometry and material of construction.
Whenever gas flows over a tube bundle, in the
in-line or staggered arrangement the vortices are
formed and shed beyond the wake of the tubes resulting in harmonically varying force perpendicular
to the flow direction. This vibration frequency is
called the vortex shedding frequency. If vortex
shedding frequency coincides with natural vibration
frequency of the tubes, the resonance occurs which
leads to bundle vibration.9 Vortex shedding can be
described by the dimensionless Strouhal number:
S=

f vs D
v cross

(1)

Strouhal number data were reviewed for tube

bundles of various configurations and tube pitch ratios (Xp = P/D)1012. Vortex shedding occurs in the
ranges 100 < Re < 105 and Re > 2 106 and dies out
in between.
Another phenomenon that occurs with vortex
shedding is the acoustic vibration, leading to noise
and high pressure drops. Standing waves are
formed inside the duct. The duct or the bundle enclosure vibrates when the vortex shedding frequency coincides with acoustic frequency. Such
resonance normally causes intense acoustic noise
and often serious tube and baffle damage. The
acoustic frequency can be predicted by the following equation:
fa =

n US
2d

(2)

The lowest acoustic frequency is achieved

when n = 1 and the characteristic length is the shell
diameter. This is called the fundamental tone and
higher overtones vibrate at acoustic frequencies 2,
3, or 4 times the fundamental (n = 2, 3, or 4) but
reports of higher overtones in heat exchangers are
rare. The velocity of the sound in a gas is given by
the equation below:
z g R q 1/ 2

U S =

(3)

The acoustic frequency always has the same

value at the inlet, centre, and outlet of the exchanger.13
Turbulent buffeting is the name given to the
fluctuating forces acting on tubes due to extremely
turbulent flow of the shell-side fluid. The turbulence has a wide spectrum of frequencies distributed around a central dominant frequency which increases as the cross-flow velocity increases. This
turbulence buffets the tubes which selectively ex-

tract energy from the turbulence at their natural frequencies from the spectrum of frequencies present.
This is extremely complex form of excitation.13 The
empirical equation of Owen14 was used to predict
this frequency:
f tb

v cross D
D

=
305
. 1 - + 028
.
Pl Pt
Pt

(4)

This equation was developed for gases and

may not be applicable to liquids.
Vortex shedding resonance and random excitation are not usually of concern in gas flow since the
fluid density is generally low thereby resulting in
relatively small excitation forces. However, both
mechanisms should be considered in some gas heat
exchangers. Acoustic resonance is possible in gas
heat exchangers and it must be avoided. The experience with similarly sized units, tube spacing and
tube size can be very helpful for predicting probability of vibration problems.

Results and discussion

Vibration analysis

A detailed calculation and vibration analysis

was made for both heat exchangers at three different locations:
1. The entrance baffle span (between the tube
sheet and the first baffle)
2. The centre baffle span (at a typical baffle
centre span location)
3. The exit baffle span (between the last baffle
and the rear tube sheet)
Table 2 shows geometry of the exchangers
E-111 and E-114.
Detailed vibration analysis includes the following steps. The first step is determination of
fluidelastic instability. Fluidelastic instability is by
far the most important mechanism and must be
avoided in all cases. It can be determined by
Connors method:15
v crit = b f n

2p z n mt
r

(5)

This topic was reviewed16 and formulated in

terms of dimensionless flow velocity, v crit /f n D and
dimensionless mass-damping parameter, 2pz n mt / rD 2 :
2p z m
v crit
n t
= b
rD2
f nD

(6)

I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

T a b l e 2 Geometry of heat exchangers E-111 and E-114

E -111

E -114

C/BEM

C/BEM

shell diameter, m

0.934

0.934

number of tubes

707

693

tube length, m

11.0

3.6

tube outer diameter, mm

25.0

25.0

triangular (30)

triangular (30)

32.0

32.0

SSEG

SSEG

baffle cut percent, %

40

25

direction of baffle cut

horizontal

horizontal

inlet spacing, m

2.06

0.26

center spacing, m

1.70

0.27

outlet spacing, m

2.06

0.26

number of baffles

12

TEMA class

tube pattern
tube pitch, mm
number of tube passes
baffle type

The results of the vibration analysis for the

heat exchanger E-111 are shown in Table 3. It may
be concluded that vibration problems exist in all
three considered locations of the E-111 heat
exchanger. Cross-flow rate is more than 10 times
greater than the critical value. The ratio of natural
frequency to vortex shedding frequency is 40.70,
indicating that resonant conditions cannot occur.
However, the ratio of vortex shedding frequency to
acoustic frequency is 1.02 and vibration of the tube
bundle may occur, causing possible damage and
noise.
T a b l e 3 Vibration analysis results for heat exchanger
E-111

The damping ratio, z n , is the total damping ratio in heat exchangers with gas on the shell-side as
defined as friction between tubes and tube-supports,
in percent:17
1/ 2
N - 1
L

zn = 5

N
lm

291

(7)

When the shell-side fluid is a gas, the Connors

method is the most important determinant of the vibration problem. If the velocity in the given span
exceeds the Connors critical velocity, then four different criteria, based on the Chen9 for vortex shedding frequency and Owen14 method for turbulent
buffeting frequency, have to be considered. So, the
second step of vibration analysis is to check that the
tube vibration level is below the permitted level and
that unacceptable resonance is avoided,18 based on
the following four criteria:
1. The ratio of vortex shedding frequency to
natural frequency is greater than 0.5.
2. The ratio of vortex shedding frequency to
acoustic frequency is greater than 0.8 and less than
1.2.
3. The ratio of turbulence buffeting frequency
to natural frequency is greater than 0.5.
4. The ratio of turbulence buffeting frequency
to acoustic frequency is greater than 0.8 an less
than 1.2.

Inlet

Center

Outlet

tube span, m

3.76

3.40

3.76

vcross, m s1

5.73

6.95

5.73

vcrit, m s1

0.69

0.65

0.61

vcross/vcrit

8.35

10.69

9.37

f n,

s1

4.75

4.75

4.75

fa, s1

223.3

212.0

200.0

fvs, s1

179.0

217.1

179.0

33.5

40.7

33.5

fvs/fn

37.70

40.70

37.70

fvs/fa

0.80

1.02

0.90

ftb/fn

7.05

8.56

7.06

ftb/fa

0.15

0.19

0.17

YES

YES

YES

ftb,

s1

vibration exists

One of the possibilities for vibration problem

removal is to use different types of baffles. A baffle
shape, cut, number, orientation, and spacing directly determine the fluid rate, which in turn has a
major influence on vibration occurrence. For five
different types of baffles, a study was made and
simulation results are shown in Figs. 6-8.
Fig. 6 shows fluid cross-flow rate dependence
on baffle spacing for five different types of baffles.
It can be seen that fluid cross-flow rate decreases
with the increased baffle spacing. Also, the lowest
cross-flow rates are achieved with double segmental and triple segmental baffles for spacing greater
than 1.0 m.
Fig. 7 also shows that a lower pressure drop
can be achieved using double and triple segmental
baffles.
Fig. 8 shows how baffle spacing and type influence the vortex shedding frequency. The value of

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I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

F i g . 6 Baffle spacing influence on fluid cross-flow rate

tex shedding frequency are achieved using double

and triple segmental baffle, in comparison with single segmental baffles, constructed in the analyzed
heat exchanger. In this case, two type of baffles,
DSEG and TSEG, shows equally good results but
DSEG baffles have the advantage because they are
specialized for reduction of cross-flow rate for a
given baffle spacing and they gave better critical to
cross-flow rate ratio then TSEG.
Based on obtained results, recommended solution of vibration problem of heat exchanger E-111
is to replace SSEG with DSEG baffles and to reduce the span between them from 1.70 m to 1.10 m
so their number have to be increased from 5 to 8. In
that case fluid cross-flow to critical rate ratio is
1.75, and the vortex shedding frequency is reduced
by 4 times. This can remove the possibility of its
coinciding with the bundles tube natural frequency
and acoustic frequency, eliminating vibration and
noise problems. This approach retains the structural
effectiveness of the tube bundle yet allows the gas
to flow between alternating tube sections in a
straighter overall direction, thereby reducing the effect of numerous direction changes.
The results obtained by simulation for 8 double
segmental baffles with 1.10 m spacing are given in
Table 4.
T a b l e 4 Results obtained by simulation for 8 DSEG baffles with 1.10 m spacing
Inlet

Center

Outlet

tube span, m

2.71

2.20

2.71

vcross, m s-1

4.58

6.71

4.58

2.11

3.82

1.89

2.17

1.75

2.42

F i g . 7 Shell pressure drop dependence on baffle spacing

vcrit, m

s-1

vcross/vcrit

F i g . 8 Vortex shedding frequency for different baffle

spacing and different baffle types

the vortex shedding frequency has an impact on the

cross-flow rate of the fluid and vibration problem in
heat exchanger. The vortex shedding frequency, in
general, drops with the increased baffle spacing. It
is important to notice that much lower value of vor-

fn, s-1

12.3

23.5

12.3

fa, s-1

223.3

212.0

200.0

fvs, s-1

36.72

53.82

36.72

ftb, s-1

3.33

4.87

3.33

fvs/fn

3.00

2.30

3.00

fvs/fa

0.16

0.25

0.18

ftb/fn

0.27

0.21

0.27

ftb/fa

0.01

0.02

0.02

Fig. 9 shows that double segmental baffles

greatly reduce vortex shedding frequency and that
the differences between other frequencies are large
enough not to coincide.

I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

293

Conclusion

F i g . 9 Comparison of NF, VSF and AF values for SSEG

and DSEG types of baffles

Vibration analysis for heat exchanger E-114

was made also and the same procedure was followed as for heat exchanger E-111. The results of
vibration analysis for E-114 are shown in Table 5.
T a b l e 5 Vibration analysis results for heat exchanger
E-114
Inlet

Center

Outlet

tube span, m

0.53

0.55

0.53

vcross, m s-1

0.25

0.24

0.25

vcrit, m s-1

5.36

5.39

5.36

vcross/vcrit

0.05

0.04

0.05

fn, s-1

205.8

205.7

205.9

fa, s-1

0.0

0.0

0.0

fvs, s-1

7.68

7.38

7.68

ftb, s-1

1.44

1.38

1.44

fvs/fn

0.04

0.04

0.04

fvs/fa

0.0

0.0

0.0

ftb/fn

0.01

0.01

0.01

ftb/fa

0.0

0.0

0.0

vibration exists

NO

NO

NO

Fluidelastic instability was determinate by

Connors method15 and from the obtained results it
can be seen that fluid cross-flow rate is below the
critical one (vcross < vcrit) which indicates that E-114
has no vibration problems. This is also confirmed
by calculated low value of vortex shedding frequency and the value of acoustic frequency equalling zero.

A detailed calculation and vibration analysis of

two heat exchangers of the nitric acid synthesis
plant were made. Based on obtained results, the following may be concluded:
Nitrous gases cooler E-111 has a vibration
problem.
Vibrations of E-111 are caused by coinciding
values of the vortex shedding frequency and the
acoustic frequency.
The vortex shedding frequency can be reduced using double segmental baffles, rather than
the existing single segmental, and therefore frequencies coinciding can be removed. This reduces
the possibility of tube bundle vibration problems
and noise.
Vibrations cannot be entirely removed, because high-rate gas flows through the shell and
tubes and the designed length of the tubes is 11.0
m.
Heat exchanger E-114 has no vibration problem.
Nomenclature

d
- shell inside diameter, m
D
- tube outside diameter, m
- tube natural frequency, s1
fn
fvs - vortex shedding frequency, s1
- first acoustic frequency of the bundle, s1
fa
ftb - turbulent buffeting frequency, s1
lm - span length, mm
lbaff - baffle spacing, m
- support thickness, mm
L
mt - linear mass density of tube, kg m1
M - molar mass, kg mol1
- mode number, dimensionless integer
n
- number of span
N
- inlet pressure, MPa
pi
Dpshell - shell-side pressure drop, MPa
- tube pitch, mm
P
Pl - longitudinal tube pitch, mm
Pt - transverse tube pitch, mm
qm - mass flow rate, kg h1
- gas constant, 8.314 J mol1 K1
R
Re - Reynolds number
- Strouhal number
S
Us - velocity of sound in the shell side fluid, m s1
vcross - cross-flow rate, m s1
vcrit - critical cross-flow rate, m s1
Xp - tube pitch ratio
- compressibility factor, dimensionless
z

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I. OLJI et al., Vibration Analysis of Heat Exchangers of a Nitric Acid Plant, Chem. Biochem. Eng. Q. 23 (3) 287294 (2009)

Greek letters

b
q
qi
qo
zn
r
g
F

- Connors constant
- absolute temperature, C
- inlet temperature, C
- outlet temperature, C
- modal damping ratio
- shell side fluid density, kg m3
- specific heat ratio, Cp/Cv
- heat load, kW

Abbreviations

C/BEM - Tema class

SSEG - single segmental baffles
DSEG - double segmental baffles
TSEG - triple segmental baffles
VSF - vortex shedding frequency
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