Aspen Exchanger Design &

Rating
Troubleshooting Vibration Problems
in Shell & Tube Exchangers

Eric Roy, Westlake Chemical Corp. & Steve Noe, Industry Marketing

2010 Aspen Technology, Inc. All rights reserved. All capabilities and dates are for planning purposes only and may not be used in any contract.
 Why be concerned about vibration ?

Mechanical damage caused by

joint failure
fatigue failure
fretting (wear)
Impact
Cost if equipment has to be replaced
Safety and reliability of operating plant

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 2

 Aspen Shell & Tube Design Mode

Avoidance of vibration problems not included in design logic

A selected design may not be vibration free
Vibration analysis now done (v7.2) for all TEMA shell types
Single phase liquid, single phase gas and two phase

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 3

 Parameters that affect vibration analysis

Impingement Protection
Tube material
Density and Youngs modulus of elasticity
Local velocities
Cross flow stream fraction
Unsupported tube lengths
inlet, C-C, outlet baffle spacings
U-bend unsupported lengths
NTIW, rod baffles
Inlet & exit areas void of tubes
Tube od, pattern, pitch

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 4

 Vibration causes Fluid Elastic Instability

One of major causes for tube failure

Occurs when local velocity > critical velocity
Energy absorbed by the tube > energy dissipated (damping)
Combination of drag & lift forces
Equation for critical velocity ucrit

FLOW

d = log-decrement - a measure of damping

fn = natural frequency, Do = tube o.d.,
Po = fluid density
me = effective tube mass, K = instability constant
All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 5

 Aspen Shell & Tube - Velocity Calculations

These are based on the minimum flow area and allow for:
bundle by-passing and baffle leakage
change in density along the unit (including two phase
units)
changes in flow direction
crossflow penetration into the window
jetting at the inlet nozzle & around impingement plate

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 6

 Fluid Elastic Instability - tubes checked

Single segmental baffles

1 1
1 - Top tube row
4 2
2 Outside baffle cut
4 2
4 Inside baffle cut
5 Bottom tube row
4 2

4 2
5 5

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 7

 Fluid Elastic Instability - probability

Indicator = YES
W / Wc > 1 for Heavy damping
W / Wc > 1 for Medium damping
W / Wc > 1 for Estimated damping

Indicator = POSSIBLE
W / Wc > 1 for Light damping

Warnings are generated for all YES or Possible situations

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 8

 Shell & Tube Fluid Elastic Instability Report

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 9

 Design Considerations to Avoid Vibration

Decrease fluid velocity

Shell type, baffle type, increase tube size or baffle pitch

Increase tube natural frequency (tube support)

Decrease baffle pitch, add intermediate supports, increase tube diameter

Remove tubes in window region

Increase damping by reducing clearances between
tubes and baffles
Reduce nozzle velocities

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 10

 Guide to optimization / eliminating potential
for vibration

Adjusted High Pressure High Pressure Low Coefficient Low Coefficient Temperature Vibration
Parameters Drop Shell side Drop Tube side Shell side Tube side Cross Indication
optimized by
program

Baffle type Double, triple - Single Segmental - - Double, triple

segmental, segmental,
RODS RODS or NTIW
Shell type J or X type shell - E or F type shell - E, F, or G type J or X type shell
shell
Tube pattern Rotated Square - Triangular - - Rotated square
or Square or Square
Tube diameter Increase to 1 or Increase to 1 or Decrease to Decrease to 0.625 - Increase to 1 or
1.25 1.25 0.625 or 0.5 or 0.5 1.25

Baffle cut Use 30% to 40% - Use 15% to 20% - - -

Tube pitch Increase to 1.4 to - Limit to TEMA std - - Increase to 1.4

1.5 x tube OD spacing to 1.5 x tube OD
Fluid allocation Switch sides Switch sides Switch sides Switch sides - Switch sides

# Tube passes - Limit to one tube - Increase # of tube Limit to one tube -
pass passes pass
Tube type Plain Plain Ext. enhanced Internal enhanced - -
tubing tubing

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 11

 Demonstration fluid elastic instability

Eric Roy of Westlake

All capabilities and dates are for planning purposes only and may not be used in any contract.

2010 Aspen Technology, Inc. All rights reserved | 12

 WESTLAKE CHEMICAL CORPORATION

Disclaimer
The contents of this presentation are solely
the opinions of the presenters and are not
representative of the opinions of Westlake
Chemical Corporation.

CONFIDENTIAL
13
 Registration Open!
AspenTech Global Conference: OPTIMIZE 2011

Come to Washington for the industrys only event focused

exclusively on optimizing Engineering, Manufacturing and
Supply Chain operations in the process industries!

Two new tracks - Optimize IT and Energy Optimization

Expanded Optimization Demo Theatre showcasing

todays most innovative technology with experts
on hand to answer your questions

A new networking tool allows you to connect with

your fellow attendees with the touch of a button!

Guest keynotes, unique evening events, roundtable

discussions on the industrys hot topics and
so much more!

Registration OPEN NOW!

2010 Aspen Technology, Inc. All rights reserved | 14

Want to see similar results?

Consider a training class from AspenTech

http://support.aspentech.com/training

2010 Aspen Technology, Inc. All rights reserved | 15

 Aspen Exchanger Design and Rating (EDR)
Training

Design and Rate a Shell & Tube Heat Exchanger:

(EHX1011)
March 11, 2011 Tokyo, Japan

May 11, 2011 Pune, India

May 30, 2011 Singapore & Virtual Asia Pacific

July 13, 2011 Melbourne, Australia

http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHX1011

Enhance understanding of thermal design of shell and tube heat exchangers

Benefit from practical experience using software in design and simulation exercises to
solve process industry problems
Develop and apply basic design and modeling skills in heat transfer
Optimize work processes using Aspen Shell & Tube Exchanger software

2010 Aspen Technology, Inc. All rights reserved | 16

 Aspen Exchanger Design and Rating (EDR)
Training

Design and Rate an Air Cooled Heat Exchanger: (EHX1021)

May 12, 2011 Pune, India

June 1, 2011 Singapore & Virtual Asia Pacific

http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHX1021

Learn the general design considerations of Air Cooled Exchangers.

Examine process side, air side, fan selection and physical properties, and
investigate thermal design principles, counter current exchangers and
extended surfaces.
Explore process-side events and responses, including single and two phase
heat transfer, boiling, condensing and fouling.

2010 Aspen Technology, Inc. All rights reserved | 17

 AspenTech Training: Making it easy

Simply by participating today you have earned a 10% training

discount to help you get started
1. You will receive a Discount Coupon. Fill in your details. This coupon is
only valid for use by the webinar attendee and is not transferable.

2. Go to AspenTech training website http://support.aspentech.com/training

and select the course you want to attend and register for the course

3. Email the completed Discount Coupon to the respective AspenTech

training coordinators in your region

4. The training coordinator will process your registration with the discounted
rate.

5. The discount expires March 31, 2011. Registration must take place before
expiration for the discount to apply. No restriction on the course date.

2010 Aspen Technology, Inc. All rights reserved | 18

Questions

2010 Aspen Technology, Inc. All rights reserved | 19

Contact Information

Eric Roy
Westlake Chemical
Email: [email protected]

Sanjeev Mullick
AspenTech (Industry Marketing)
Email: [email protected]

Steve Noe
AspenTech (Industry Marketing)
Email: [email protected]

2010 Aspen Technology, Inc. All rights reserved | 20