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Journal of Failure Analysis and Prevention

, Volume 17, Issue 3, pp 581–594 | Cite as

Estimation of Fretting Wear-Limited Life of a Shell and Tube Heat Exchanger Tubes: Analytical Formulation, Computer Implementation and Qualification Against Actual Reported Failure

  • Gajendra Vasantrao Patil
  • M. A. Dharap
  • R. I. K. Moorthy
Technical Article---Peer-Reviewed

Abstract

In a typical shell and tube-type heat exchanger, the tubes are clamped at the ends by tube sheets and supported by intermittent baffles with gaps. Vibration of tubes makes them susceptible to impacting and rubbing with the baffle support or adjacent tubes. Damage caused by these impacts and rubbing motions is termed fretting. An analytical tool is developed to carry out fretting wear-limited life of heat exchanger tubes. The developed tool is evaluated with reported cases of failure. The authors had earlier conducted this evaluation (Patil et al. in J Fail Anal Preven 17:126–135, 2017) in cases where the vibration was excited by vortex shedding. This paper extends the study to include the other flow-induced mechanism of turbulent buffeting, thus making the tool more comprehensive.

Keywords

Fretting Shell and tube heat exchanger Vortex shedding Turbulent buffeting premature failure 

List of symbols

ρ

Fluid density

ν

Free stream velocity

\(f_{n}\)

Reduced frequency

D

Tube diameter

CL

Lift coefficient, dimensionless

ωs

Circular vortex shedding frequency, radian/s

FL

Lift force (force perpendicular to the mean flow) per unit length of tube

ρV

Mass flux

SFF

Power spectral density

\(\emptyset_{i}\)

Phase angle

N

Number of harmonics contributing to the total force

Le

Element length

M

Mass matrix

C

Linear damping matrix

CNL

Nonlinear damping matrix

K

Linear stiffness matrix

KNL

Nonlinear stiffness matrix

\(R_{{t +\Delta t}}\)

External force vector at time \(t +\Delta t\)

\(\ddot{U}_{{t +\Delta t}}\), \(\dot{U}_{{t +\Delta t}}\), \(U_{{t +\Delta t}}\)

Acceleration, velocity and displacement vectors at time \(t +\Delta t\), respectively

f

Contact force

KNL

Support stiffness

U

Displacement between tube and support

CNL

Nonlinear damping coefficient

\(V\left( t \right)\)

Worn volume after time \(T\)

k

A specific wear coefficient

FN

Normal contact force between tube and support

L(t)

Sliding distance after time T

\(\dot{V}\)

Fretting wear damage volume rate

KW

Specific wear coefficient

WN

Normal work rate

L

Support thickness

dW

Tube wall wear depth

CR

Random excitation force coefficient

TEMA

Tubular exchanger manufacturer association

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Copyright information

© ASM International 2017

Authors and Affiliations

  • Gajendra Vasantrao Patil
    • 1
    • 2
  • M. A. Dharap
    • 1
  • R. I. K. Moorthy
    • 2
  1. 1.Veermata Jijabai Technological InstituteMumbaiIndia
  2. 2.Pillai College of EngineeringMumbai UniversityNew PanvelIndia

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