Numerical Study and Structural Optimization of Guided Bearing Heat Exchanger with Impurity-Contained Cooling Water

The cooling medium of the guide bearing heat exchanger in hydro generator sets comes from the upstream dam area, which contains numerous impurities even though it has undergone preliminary treatment. These impurities settle, accumulate, and adhere and form scaling layers in the heat exchanger, seriously affecting its heat transfer performance. This paper presents an innovative investigation of heat exchanger performance under impurity-laden cooling water conditions and proposes an optimization by replacing the conventional round tube structure with a spiral flat tube structure. Numerical simulations are conducted to analyze the flow velocity, pressure, impurity deposition, and temperature distribution of the cooler under actual operating conditions. The results show that the optimized cooler achieves improved velocity uniformity with a lower standard deviation, effectively reducing sediment accumulation. Compared to the prototype, the maximum pressure increases by 55.2% (from 0.562 MPa to 0.872 MPa), which enhances turbulence and improves heat transfer. The sediment volume fraction is significantly reduced by 49% in low-flow operating conditions and 73.7% in high-flow operating conditions. Furthermore, the maximum temperature drops by 5.43 °C, indicating improved thermal performance. These findings confirm the effectiveness of the spiral flat tube design in impurity-rich environments.