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Customized Design High-Efficiency Heat-Exchange Air Cooler with Modular Maintainable Structure for Hydro-Generator

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Chongqing Huanxiang Industrial. Co., Ltd.

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Customized Design High-Efficiency Heat-Exchange Air Cooler with Modular Maintainable Structure for Hydro-Generator

Tube material : Copper with aluminum fin

Hydraulic design : Low-resistance optimized flow channel

Heat-exchange core : Finned tube bundles

Anti-corrosion protection : Epoxy coating or hot-dip galvanizing

Optional tubes : Stainless steel / copper-nickel alloy

Structure type : Drawer-type modular or integral box-type

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Customized Air Cooler for Hydroturbine

The air cooler is an indispensable heat-exchange device for closed-circulation air cooling systems in hydro-generators. During generator operation, copper loss and iron loss produce massive heat that warms the internal circulating air. The air cooler efficiently transfers heat from the hot generator air to cooling water via finned tube bundles, then returns the cooled air back into the generator chamber, forming a continuous closed-loop cooling circulation.

Insufficient cooling capacity or leakage can cause generator winding temperature to rise sharply, accelerating insulation aging, reducing unit output, and potentially triggering over-temperature shutdown and safety hazards.

Custom Engineering Solutions

We provide tailor-made air cooler solutions based on customer drawings, generator rated capacity, installation space, cooling water quality, ambient humidity, and corrosive environment requirements. Both drawer-type modular structure and integral box-type structure are available for different unit configurations.

Main Technical Features

High-efficiency heat-exchange core: High-performance finned tube bundles with copper tubes and aluminum fins for superior heat transfer efficiency. Stainless steel or copper-nickel alloy tubes available for poor-quality cooling water to resist scale, corrosion, and erosion.
Modular maintainable structure: Drawer-type design allows individual cooling bundles to be pulled out separately for inspection and replacement without dismantling the entire air cooler, significantly reducing overhaul time.
Reliable anti-leakage performance: Optimized tube-to-tube-sheet welding process with strict water pressure leakage testing to prevent cooling water leakage into generator chamber.
Custom anti-corrosion protection: Epoxy coating or hot-dip galvanizing for shell and fin surfaces, suitable for humid workshops, coastal salt-spray environments, and high-altitude hydropower stations.
Low-resistance hydraulic design: Optimized flow channel layout reduces water-side and air-side pressure drop, lowering auxiliary pump power consumption while maintaining stable cooling under variable load conditions.

Application Scope

Complete equipment supply for new-built hydropower stations
Generator refurbishment, capacity-increase retrofitting, and cooling-system upgrading
Overhaul spare-part replacement for Francis, Kaplan, bulb, and pumped-storage reversible generator sets
Medium and large hydropower plants, EPC contractors, and power asset operators worldwide

Our Services

Custom design and fabrication according to customer drawings or technical specifications
Material and anti-corrosion scheme optimization for poor-quality cooling water, humid, or salt-spray environments
Comprehensive factory testing: hydraulic pressure leak tests, appearance and dimension inspection, heat-exchange performance verification
Technical support for transportation, field installation, commissioning, and maintenance guidance

Please share your generator parameters, drawings, or working-condition requirements. We will prepare targeted technical proposals and quotations for your specific application.

Product Tags:

High-Efficiency Heat-Exchange Air Cooler

Customized Heat-Exchange Air Cooler

Customized Design High-Efficiency Heat-Exchange Air Cooler with Modular Maintainable Structure for Hydro-Generator Images

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