DFO Melbourne Cooling Tower Corrosion Repair

FlowMatrix BAC crossflow cooling tower repair at DFO Melbourne.

Project Details:

Client

HydroChem Pty Ltd

Project Status

Completed

Job Type

Commercial cooling tower repair

Year Completed

2021

Project Overview

FlowMatrix carried out a comprehensive repair on a BAC cross-flow cooling tower at DFO Melbourne.

The steel basin was severely corroded, with holes developing that leaked water and chemicals onto the ground and into stormwater systems.

Two basins required coating to eliminate corrosion and stop water leaks. To facilitate the coating process, the fill pack on the BAC had to be removed to access the basin area.

Understanding the BAC Cross-Flow Design:

BAC crossflow cooling towers feature OEM sheets supported by steel bars passing through holes in the sheets. These sheets slide over the bars and interlock, forming a solid fill pack approximately 1300 mm wide from front to back.

Due to the design, removing and replacing these fill packs is extremely challenging — often requiring cutting out the old fill and disposing of it, which complicates maintenance and repairs.

Innovative Solution:

To improve future maintenance and compliance with environmental regulations, FlowMatrix installed modular PVC Brentwood fill pack blocks.

These blocks, measuring 300 mm wide by 600 mm deep and weighing around 10 kg each when clean, are easy to remove, clean, and refit. The process involves power washing the outside of the tower, then removing the modular fill for cleaning or replacement, significantly reducing downtime.

What we achieved:

Eliminated corrosion in the basin area up to the underside of the coil.
Applied the RepelCoat three-coat coating system, which is flexible, durable, chemical resistant, and smooth for easy cleaning.
Installed modular PVC fill blocks that are simple to handle, clean, and reinstall.
Removed corroded steel bars and replaced them with non-corrosive fibreglass supports underneath the fill pack, allowing quick basin washing.
Enhanced maintenance efficiency, enabling dirt, scale, and bacteria removal with minimal effort.

Why Modular Fill Packs Outperform OEM Sheet Fills:

OEM sheet fill packs may offer superior cooling performance when brand new, but over time, they tend to clog with dirt and scale, making cleaning difficult. In situ cleaning is nearly impossible due to their tightly packed design and length (1300 mm), which hampers effective maintenance.

In contrast, modular fill packs can be easily removed for power washing, ensuring sustained cooling efficiency over many years. If the basin is damaged, the fill pack can be quickly removed for repairs — eliminating the need for costly replacements of the entire sheet fill system.

FlowMatrix provides innovative, modular cooling tower repair solutions that simplify maintenance, enhance performance, and reduce operational costs.

Connect with us today to explore how our expertise can deliver a precise solution for your requirements.