At FlowMatrix, we specialize in providing comprehensive repair and rebuild solutions for cooling towers across industrial and commercial facilities. We feature today two recent projects – Industrial job at Fosterville Gold Mine and a commercial job for HydroChem. These jobs exemplify our commitment to safety, efficiency, and technical excellence, ensuring our clients’ operations run smoothly with minimal downtime.
Project Overview: Industrial – Superchill Cooling Tower at Fosterville Gold Mine
Our team was engaged to perform critical repairs on the Superchill Cooling Tower located at Fosterville Gold Mine. Our scope involved removing the old PVC fill pack and replacing the fill pack with a low fowling fill pack, the installation of a fibreglass fill pack supports that also provide ongoing safe access for maintenance. The project ensuring the tower’s optimal cooling performance for continued industrial operations in dirty water and air conditions.
Superchill cooling tower on site
Detailed project process
Install low fowling fill pack and safe support and work area
Pre-Work Planning: We commenced with securing all necessary site permits, completing Job Safety Analyses (JSA), setting up confined space entry permits and equipment, to prioritize safety at every stage.
Material Handling: Our team efficiently loaded all required materials onto site, ensuring timely availability for the task ahead.
Site Isolation: The site contact performed essential isolations, while our FMX staff applied personal locks and tags, maintaining strict lockout-tagout procedures.
Access and Removal: We removed the access hatch and carefully took out the old fill pack, disposing of debris responsibly into designated site bins.
Old fill pack parts before work
Installation of New Components: New FRP fibreglass supports, and walkway mesh installed to support the new modular block fill pack. We precisely cut and installed the strong and non-corrosive fibreglass materials. We then installed the low fowling Brentwood TX19 counterflow fill pack blocks, ensuring compatibility and performance. This material increases the water-cooling performance by stopping clogging of the fill pack in dirty air and water conditions.
Old dirty and fowled pack before installation
Old fill pack removed
FRP fibreglass support mesh installed
Brentwood TX19 low fowling counterflow fill pack blocks installed
Drift eliminator reinstalled – Modern and modular design
Clean-up & Reinstatement: After completing the installation, all debris was cleared from the scaffolding platform and the cooling tower associated pit. Our team packed up equipment and rubbish, removed all personal locks and tags, and closed permits, CSE permits, and the JSA. A comprehensive report was given to the client on successful completion of the job.
Outcome
FlowMatrix’s comprehensive approach ensured minimal downtime and maximum adherence to safety standards. The upgraded Superchill Cooling Tower at Fosterville Gold Mine is now ready to operate at peak efficiency, supporting the mine’s ongoing production needs.
Ongoing maintenance of the fill pack, the water distribution system, the drift eliminators is so much safer now as maintenance personnel can safely walk on the new FRP fibreglass supports and walkway mesh above the original fall potential into the basin pit below.
Project Overview: Commercial – Aquacool Cooling Tower for HydroChem
Install low fowling fill pack and high-performance drift eliminators
Our team was engaged to perform a comprehensive repair upgrade the Aquacool Cooling Tower, to increase the optimal water-cooling performance and compliance with safety standards. The project involved a complete overhaul of the drift eliminators and fill pack, including upgrading the heat exchange medium, the fill pack to a low fowling TX-19 modular block material to enhance the tower efficiency.
Aquacool Cooling Towers on a commercial site
Detailed Project Process
Preparation & Safety Compliance: FlowMatrix completed a thorough Job Safety Analysis (JSA) and secured all necessary permits before commencing work. The unit was securely locked out-tagged out to guarantee safety during the operation.
Drainage & Access: The cooling tower basin was drained chemical dosing isolated to facilitate safe working assess. The main access hatches were then removed to allow full access to the tower internals, the fill pack and the drift eliminators.
Component Removal & Disposal: Old drift eliminators and fill pack were carefully removed and disposed of off-site, ensuring environmentally responsible waste management.
Old damaged and scaled drift eliminators
New Drift eliminators installed – front view of the tower
New Drift eliminators installed – view from the water distribution system below
Installation of New Components: We supplied and installed non-corrosive FRP fibreglass angle air seals and supports for the drift eliminators, followed by the installation of new Brentwood CF ULTRA drift eliminators. We then installed the modern low fowling – high water-cooling performance – Brentwood TX19 counterflow fill pack, optimize the ongoing water-cooling efficiency.
Old Fill pack before installation
New low fowling fill pack installed – front view of the cooling tower
View of the water distribution before the new drift eliminators were installed
New drift eliminator air seal installed
Reassembly & Testing: The access hatch was reinstalled, and the unit was de-isolated. Our team then performed operational checks to confirm correct operation of the system.
Final Documentation: All permits and JSAs were closed. A comprehensive report, including detailed photos of each stage, was completed to document the work and ensure transparency.
Our Dedicated Team
Led by experienced technicians, our team ensured every step was performed with the highest safety standards and technical precision.
Why Choose FlowMatrix?
- Extensive Experience: Proven success with both industrial and commercial cooling tower projects.
- Safety-First Approach: Strict adherence to site protocols, permits, JSAs, and lockout procedures.
- Technical Excellence: Skilled technicians delivering reliable, high-quality results.
- Detailed Documentation: Comprehensive reports with photos for transparency and client records.
- Customer-Centric Service: Tailored solutions to meet each client’s specific needs.
Contact Us
Whether you need industrial or commercial cooling tower repairs, trust FlowMatrix to deliver expert solutions with safety and quality at the forefront. Reach out today to discuss your project or request a quote!
FlowMatrix — Your Trusted Partner in Cooling Tower Repairs.
