--- title: Case study Dresser-Rand Oil Cooler | Bronswerk Heat Transfer description: For a global oil & gas company we designed, manufactured, and delivered a very special Oil Air-Cooled Heat Exchanger. Read the case study. --- [![Bronswerk Heat Transfer](https://www.bronswerk.com/hs-fs/hubfs/website_assets/logo-2.png?width=235&height=44&name=logo-2.png "Bronswerk Heat Transfer")](https://www.bronswerk.com/) - [Industries](https://www.bronswerk.com/industries) - [Oil](https://www.bronswerk.com/oil-industry) - [Gas](https://www.bronswerk.com/gas-industry) - [Chemical](https://www.bronswerk.com/chemical-industry) - [Power](https://www.bronswerk.com/power-industry) - [Food](https://www.bronswerk.com/food-industry) - [Pulp & Paper](https://www.bronswerk.com/industry-pulp-paper) - [Expertise](https://www.bronswerk.com/our-expertise) - [Customer Needs & Requirements](https://www.bronswerk.com/customer-needs-and-solutions) - [Project Management](https://www.bronswerk.com/project-management) - [Performance & Reliability Improvement](https://www.bronswerk.com/performance-and-reliability-improvement) - [Innovation & Sustainability](https://www.bronswerk.com/innovation-sustainability) - [Process Equipment from Exotic Materials](https://www.bronswerk.com/process-equipment-exotic-materials) - [Project Specific Manufacturing](https://www.bronswerk.com/project-specific-manufacturing) - [Case studies](https://www.bronswerk.com/case-studies) - [Solutions](https://www.bronswerk.com/solutions) - [Air-Cooled Coolers](https://www.bronswerk.com/air-cooled-coolers) - [Shell & Tube Heat Exchangers](https://www.bronswerk.com/shell-tube-heat-exchangers) - [Heat Transfer Systems](https://www.bronswerk.com/heat-transfer-systems) - [Request for Quotation](https://www.bronswerk.com/request-for-quotation) - [Services](https://www.bronswerk.com/services-and-maintenance) - [Request for Quotation](https://www.bronswerk.com/request-for-quotation) - [News](https://www.bronswerk.com/news) - [Contact](https://www.bronswerk.com/contact) - [Request for Quotation](https://www.bronswerk.com/request-for-quotation) [![search](https://www.bronswerk.com/hubfs/search-icon-white.svg) ![search](https://www.bronswerk.com/hubfs/search-icon.svg)](https://www.bronswerk.com/hs-search-results) [Call us: + 31 33 24 72 500](tel:0031332472500) Case study ![1.04 High pressure Air Cooled Heat Exchanger foto 09](https://www.bronswerk.com/hubfs/Images/Air-Cooled%20Coolers%20fotos/1.04%20-%20High%20pressure%20solid%20block%20header%20-%20ache/1.04%20High%20pressure%20Air%20Cooled%20Heat%20Exchanger%20foto%2009.jpg) ## How we designed an Air-Cooled Cooler without turbulators How we designed an Air-Cooled 12 Pass Oil Equipment Cooler without turbulators for a global oil & gas company in the Middle East. Passionate about heat exchange. [To all case studies](https://www.bronswerk.com/case-studies) Our solution ## 70% ### less plot space & cost reduction The **project in short** - Project: Taweelah Gas Station - Client: OEM Dresser-Rand - End client: ADNOC - Product: Solid Block Header - Industry: oil, gas, chemical - Design: Equipment Cooling Oil/Glycol Cooler - Material: SS316L ![Equipment Cooler (lube oil & glycol)](https://www.bronswerk.com/hubfs/Images/Air-Cooled%20Coolers%20fotos/1.12%20-%20equipment%20cooling%20(lube%20oil%20and%20glycol%20cooler)/1.12%20-%20equipment%20cooling%20(lube%20oil%20%26%20glycol%20cooler)%20foto%2001.jpg) ## Efficient Air-Cooled Cooler despite restrictive conditions For an international well-known oil & gas company in the Middle East, Abu Dhabi region, we designed, manufactured, and delivered an Oil Air-Cooled Heat Exchanger. For Oil Coolers, tabulator inserts are typically used to increase the heat transfer coefficient and reduce the equipment size. Since the end user did not allow the use of tube enhancement, we used our ingenious solid block header construction to make a 12-row with a 12-pass design. This allowed us to fully comply with the strict requirements and client specifications, with only 30% of the plot space of a conventional design. #### Customer challenge Our customer was in need of an Air-Cooled Heat Exchanger that cools lube oil for their turbine package. In their specifications they did not allow the use of tube inserts to improve the tubular flow. Furthermore, the client did not allow multiple passes per row, which in combination with the other designs would result in a rather large plot pace and significantly increased CAPEX. #### Our approach At Bronswerk Heat Transfer we always focus on the customer’s needs and we use our experience to design equipment that maximizes performance. We start by diving into the customer’s specifications to mark all the requirements that impact the design of the equipment. Our thermal design department then uses the international well-known thermal calculation program HTRI to convert the received process data, combined with the specifications, into an equipment design.  The tube enhancement is not allowed in this case but we do know that the higher the fluid flow the better the heat transfer coefficient, which decreases the size of the equipment.  We designed the equipment with the maximum number of passes to have the highest heat transfer coefficient. This was only possible by implementing our patented Solid Block Header construction, allowing the customer to get the smallest design possible. #### The solution This construction enabled us to make a 12-row, 12-pass design. This solid block plug type header is machined from one solid piece of material instead of welded from plates. This means 90% fewer welds. The header construction is both efficient for high-pressure (\>100 bar) applications and for sour service, hydrogen service and lethal service. This Air-Cooled Cooler Header accedes the requirements of API 661 and is often used for high-spec projects in the (petro)chemical industry. Do you have a challenge? [Contact our specialists \>](https://www.bronswerk.com/contact) ## Innovative customized Heat Transfer Solutions since 1940 [![Air Cooler](https://www.bronswerk.com/hubfs/Images/Air-Cooled%20Coolers%20fotos/1.04%20-%20High%20pressure%20solid%20block%20header%20-%20ache/1.04%20High%20pressure%20Air%20Cooled%20Heat%20Exchanger%20foto%2013.jpg)](https://www.bronswerk.com/api-661-air-cooler) #### [Associated Product](https://www.bronswerk.com/api-661-air-cooler) More about the Solid Block Header also known as API 661 Air Cooler. [Solid Block Header](https://www.bronswerk.com/api-661-air-cooler) [![Equipment cooling / lube oil & glycol cooler](https://www.bronswerk.com/hubfs/Images/Air-Cooled%20Coolers%20fotos/1.12%20-%20equipment%20cooling%20(lube%20oil%20and%20glycol%20cooler)/1.12%20-%20equipment%20cooling%20(lube%20oil%20%26%20glycol%20cooler)%20foto%2001.jpg)](https://www.bronswerk.com/equipment-cooler) #### [Associated Product](https://www.bronswerk.com/equipment-cooler) Learn more about the benefits of our Equipment Coolers. [Equipment Cooler](https://www.bronswerk.com/equipment-cooler) [![Design optimization Air-Cooled Heat Exchangers](https://www.bronswerk.com/hubfs/Images/Air-Cooled%20Coolers%20fotos/1.06%20-%20design%20optimization%20air%20cooeld%20heat%20exchangers/1.06%20-%20design%20optimization%20air%20cooeld%20heat%20exchangers%20foto%2001.jpg)](https://www.bronswerk.com/design-optimization-air-cooled-cooler) #### [Design optimization](https://www.bronswerk.com/design-optimization-air-cooled-cooler) Learn what design optimization means for your Air-Cooled Heat Exchangers. [Design Optimization](https://www.bronswerk.com/design-optimization-air-cooled-cooler) ![Headquarters Bronswerk Heat Transfer](https://www.bronswerk.com/hubfs/Images/Shell%20and%20tube%20heat%20exchangers%20fotos/2.01%20-%20TEMA%20type%20shell%20and%20tube%20heat%20exchangers/2.01%20-%20TEMA%20type%20shell%20%26%20tube%20heat%20exchangers%20foto%2006.jpg) ## Let’s talk about your challenge Do you need a custom solution? Or do you have a question or a request? Our specialist will contact you soon ![Bronswerk](https://www.bronswerk.com/hubfs/website_assets/logo_tagline.svg) Page 26251096855 Case study Dresser-Rand Oil Cooler | Bronswerk Heat Transfer © 2026 Bronswerk