Mon–Fri 9:00 AM – 5:00 PMHouston, TX · Gulf Coast & nationwide
ACHE · AIR COOLED HEAT EXCHANGERS

Air cooled heat exchanger performance.

Maximize reliability, optimize performance and reduce cost. Full assessment and improvement of air cooled heat exchangers, air cooled condensers and cooling towers, regardless of OEM make or type.

The challenge

Higher targets, aging equipment.

Plant operators face higher productivity goals and profit targets while energy costs, operating expenses and budgets move the wrong way. Plant conditions can also change quickly, from a sudden increase in production to gradual wear and corrosion that degrades the system.

Our technical specialists combine extensive hands-on experience with mechanical and materials engineering knowledge, and pair it with practical operating and business solutions.

A-frame air cooled condenser unitsAir cooled condenser
What we help you achieve

Reliability, capacity and lower energy use.

Our programs target the outcomes that matter to operations and to the bottom line.

  • Improve equipment reliability and performance
  • Reduce energy consumption
  • Reduce noise
  • Vibration reduction and analysis
  • Optimize spare parts inventory
  • Increase availability and output of air fin coolers (AFC), air cooled condensers (ACC) and cooling towers (CT)
  • Develop and enhance workforce knowledge
  • Improve the safety and environmental impact of operations
Our method

From 'is' to 'should be'.

We evaluate the total life cycle implications of every issue. First we quantify the current economic impact, then we measure and analyze to build a foundation for recommendations, and we stay through execution.

01

Quantify

Economic and technical assessment of the problem.

02

Measure

Full onsite survey with the latest measuring techniques.

03

Analyze

HTRI® thermal simulation of actual vs. design performance.

04

Improve

Re-rates, upgrades, retrofits and asset optimization.

05

Control

KPIs and performance-based partnerships.

As a member of HTRI®, we use its thermal simulation software to compare actual air cooled heat exchanger performance with design data, the 'is' versus the 'should be'. With a flexible commercial approach, Blue Industrial then contracts with customers to carry programs through to a successful conclusion.

Thermal image of a finned tube bundle showing uneven temperatures
Thermal imaging highlights uneven airflow and fouling across a bundle.
ACHE performance capabilities

Maximize reliability. Optimize performance. Reduce cost.

Six service lines that cover the full life of an air cooled heat exchanger, from the first baseline test to verified post-upgrade results.

Mist system cooling the inlet air of an air cooled heat exchanger

COOLINGMIST™ evaporative cooling

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Up to 40% additional heat-duty capability.

  • Engineered nozzle and mist distribution systems
  • High-ambient temperature performance enhancement
  • ACHE inlet-air temperature reduction
  • System design and application engineering
Clean finned tubes after BlueBLAST cleaning

Fin-fan cleaning: BlueBLAST

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  • Non-toxic, biodegradable formulation
  • Online and offline cleaning
  • Deep fin-pack cleaning
  • Fouling and debris removal
  • Fin straightening and inspection
  • Airflow and heat-transfer restoration
  • Pre- and post-cleaning performance evaluation
Recirculation screens installed on an air cooler bank

Hot air recirculation screens

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  • Hot air recirculation mitigation
  • ACHE airflow management
  • Discharge and intake air separation
  • Site-specific screen design and layout
Air cooler structure during inspection

Mechanical & structural inspections

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  • Structural and support inspections
  • Fan and drive component inspections
  • Alignment and bolting verification
  • Tube bundle and fin assessment
  • Corrosion and condition assessment
  • Deficiency reporting and repair recommendations
Upgraded high-efficiency air cooler fan

Mechanical & performance upgrades

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  • Fan and drive system upgrades
  • Fan pitch and airflow optimization
  • Belt, sheave and bearing improvements
  • Vibration correction
  • Tip-clearance and air-sealing optimization
  • Performance testing and verification
Thermal image of a finned tube bundle

Performance testing

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  • Baseline performance testing
  • Airflow and temperature measurement
  • Fan RPM and blade pitch verification
  • Motor load and vibration analysis
  • Thermal performance evaluation
  • Design vs. actual performance analysis
  • Post-upgrade performance verification
Trend chart comparing outlet temperature with a misting system off, at 20 percent and at 45 percent
COOLINGMIST™ field trend data: system off, 20% on and 45% on.
COOLINGMIST™

Up to 40% more heat duty on hot days.

Evaporative cooling lowers the inlet-air temperature to your air coolers, recovering capacity when high ambient temperatures limit production. Every system is engineered for the unit, from nozzle selection and mist distribution to controls.

Find out what your coolers should be delivering.

We can fully assess the performance of your air cooled heat exchangers, regardless of OEM make or type.