Introduction
DHD was engaged to upgrade the fill pack system in BAC Series 3000 Cooling Towers at a food manufacturing plant.
The existing fill pack had deteriorated over time, becoming brittle and inefficient, necessitating a complete replacement.
The Challenge
The existing support structure beneath the block-type fill pack was inadequate, as it was not properly tied to the main structural supports.
A new, robust support system had to be designed and installed.
The entire project had to be completed within a strict two-week window to minimize disruption to plant operations.
The Solution
DHD implemented a structured approach to ensure a successful and timely upgrade:
Reinforced Support Structure: A new steel support bar was designed and installed, securely tied into the main structural framework.
GRP Grid Installation: A durable GRP (Glass Reinforced Plastic) grid was placed over the new support steelwork, providing a stable foundation for the fill pack.
Drift Eliminator System: A separate bank of drift eliminators was installed to enhance long-term protection by reducing the risk of drift release and minimizing legionella risk.
Upgraded Air Inlet System: New air inlet honeycomb panels were installed to improve airflow and overall system efficiency.
The Benefits
DHD successfully delivered the project with:
On-Time Completion: All work was executed within the required two-week timeframe, ensuring minimal disruption to the plant’s operations.
Improved Efficiency: The new fill pack and airflow components enhanced cooling tower performance and longevity.
Enhanced Safety & Compliance: The upgraded system minimised the risk of airborne contaminants, aligning with industry health and safety standards.
This successful installation highlights DHD’s expertise in delivering tailored cooling tower solutions for food manufacturing and other industrial applications.
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