The project involved replacing a worn-out plate-fin cooler responsible for cooling compressed air extracted from the 13th stage of a gas turbine compressor. The system used ambient air forced through the cooler by a dedicated fan arrangement.
Unlike a standard retrofit, the new unit could not simply replicate the existing design. The operating conditions were extremely demanding:
• Operating pressure: 300 psi / 20 bar
• Operating temperature: 960°F / 515°C
• Strict geometric limitations due to the existing installation layout
• Requirement for long-term reliable operation
The customer’s previous solution had limited durability and insufficient long-term reliability under these harsh operating conditions. The objective was to develop a more robust and thermally efficient solution while maintaining compatibility with the existing installation.
Based on our experience in demanding industrial applications, AHE selected Flat Tube – Fin technology as the optimal solution.
This technology offers significant advantages in terms of joint quality and overall component integrity, providing excellent resistance to high temperatures, pressure loads, and demanding operating environments.
Detailed thermal calculations confirmed that the proposed heat exchanger design would achieve the required cooling performance.
The design department prepared complete mechanical and welding documentation in accordance with applicable regulations and requirements for pressure heat exchangers.
One of the key advantages of the project was that all manufacturing and testing processes were performed at AHE’s production facilities, including:
• Component manufacturing
• Brazing processes
• Welding operations
• Final assembly
• Pressure testing
• Leak testing
• Quality control inspections
Maintaining full control over every production stage allowed the AHE team to ensure high quality standards throughout the entire manufacturing process.
Two fully customized heat exchangers were manufactured and supplied to the customer.
The units were designed to fit directly into the existing installation while meeting the required thermal and mechanical performance criteria.
Key outcomes:
• Two fully customized heat exchangers manufactured and supplied
• Designed to fit directly into the existing installation
• Engineered for 300 psi / 20 bar and 960°F / 515°C operating conditions
• Manufactured, tested and inspected at AHE’s production facilities
• Designed to support stable cooling performance and long-term reliable operation
AHE was selected by a company in Spain to design and manufacture a high-performance replacement air cooler for a high-temperature, 13th stage gas turbine compressor application. The existing unit showed limited durability and insufficient long-term reliability under severe operating conditions.
The new solution was required to operate at 20 bar / 300 psi and 515°C / 960°F, while maintaining strict geometric compatibility with the existing installation. Due to the demanding thermal and mechanical conditions, a complete redesign was necessary rather than a direct replacement.
AHE engineers selected Flat Tube – Fin technology to ensure high structural integrity and reliable performance under extreme pressure and temperature. The units were fully engineered, manufactured, and tested in-house, ensuring full quality control across all production stages.
The project resulted in two custom-designed heat exchangers intended to deliver stable cooling performance and support long-term reliable operation in a highly demanding turbine environment.
