Introduction
DHD was approached by a plastics manufacturer experiencing repeated failures in their belt-driven fan cooling towers. The bearing housings on the fan shaft frequently failed, leading to plant outages and production losses.
With a planned shutdown in October, the client sought a long-term solution to be implemented within this window.
The Challenge
The client initially proposed switching to a gearbox-driven fan system and requested DHD’s feasibility assessment for retrofitting this into their existing cooling towers.
DHD used SolidWorks software to create a detailed model and evaluate possible solutions.
Within a week of collaboration, a viable design was finalised using readily available components to meet the shutdown deadline.
The Solution
DHD executed the retrofit efficiently by:
Removing the outdated belt-drive system and externally mounted motor.
Designing a robust ring-beam support structure with an external motor platform.
Installing a new gearbox-driven system, complete with a fiberglass driveshaft for smooth operation.
The Benefits
DHD provided:
Increased Reliability: The new gearbox-driven system reduced maintenance needs and minimised unexpected downtime.
Improved Efficiency: Optimised fan performance enhanced cooling efficiency.
Successful Execution: The upgrade was completed within the planned shutdown, ensuring seamless integration into plant operations.
This innovative cooling solution ensured enhanced operational efficiency while meeting strict noise and installation requirements, showcasing DHD’s expertise in delivering tailored cooling systems for plastics manufacture and industrial applications.
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