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Design Optimization of Shell and Tube Heat Exchanger by Vibration Analysis
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Abstract In this paper a simplified approach to optimize the design of Shell Tube Heat Exchanger [STHE] by flow
induced vibration analysis [FVA] is presented. The vibration analysis of STHE helps in achieving optimiza-
tion in design by prevention of tube failure caused due to flow induced vibration. The main reason for tube
failure due to flow induced vibration is increased size of STHE. It is found that in case of increased size of
STHE, the surface area and number of tubes increases, thus the understanding and analysis of vibration be-
comes a very difficult task. Again it is found that flow induced vibration analysis is considered as an integral
part of mechanical & thermal design of STHE. The detailed design, fabrication, testing and analysis work
was carried out at Alfa Laval (India), Ltd., Pune-10.5494
Keywords: Heat Exchanger, Flow-Induced Vibration, TEMA, HTRI
1. Introduction
The principal culprit in flow induced vibration of tubes
of STHE is the unsupported tube lengths subjected to
large flow rates on shell side. The increased size of
STHE due to large flow rates is responsible for vibration
of tubes, which further leads to tube failure. Also the
design of STHE is made safer by modifying shell type
and/or baffles style and baffle design. Thus, the vibration
analysis is of utmost importance in design of STHE. So,
the flow induced vibration analysis is considered as an
integral part of thermal design.
The characteristics of vortex shedding from tube banks
with closely mounted serrated fin was investigated in [1]
where the relationship between the Strouhal number de-
fined by the equivalent diameter as the characteristic
length of a finned tube in the tube banks and the Strouhal
number map for bare-tube banks was examined. Whereas
in [2] the author has presented various outlet conditions
of a shell and tube heat exchanger theoretically and ex-
perimentally in which it is observed that prime parameter
geometry of outlet affects the performance, maintenance
and life span of a vertical shell and tube evaporator. The
heat transfer enhancement has been achieved in [3], by
modifying the configuration of a shell-and-tube heat ex-
changer, through the installation of sealers in the shell-
side. The gaps between the baffle plates and shell is
blocked by the sealers, which effectively decreases the
short-circuit flow in the shell-side. The original short-
circuit flow then participates in heat transfer, which in-
tensifies the heat transfer performance inside the heat
exchanger. The use of a non-traditional optimization tech-
nique; called Particle Swarm Optimization (PSO), for
design optimization of shell-and-tube heat exchangers
from economic view point is explored in [4] in which
minimization of total annual cost is considered as an ob-
jective function. Three design variables such as shell
internal diameter, outer tube diameter and baffle spacing
are considered for optimization. Two tube layouts viz.
triangle and square are also considered for optimization.
The results of optimization using PSO technique are
compared with those obtained by using Genetic Algo-
rithm (GA). Also the optimization of the design of shell-
and-tube heat exchangers by minimization of the thermal
surface of the equipment, for certain minimum excess
area and maximum pressure drops, considering discrete
decision variables is presented in [5]. The heat transfer
coefficient and pressure drop on the shell side of a
shell-and-tube heat exchanger has been obtained experi-
mentally in [6] for three different types of copper tubes.
The comprehensive experimental investigation on the