Cooling Tower Mechanical Overhaul at Melbourne University

This project involved the installation of a new fan motor, bearings, shaft, pulleys, bushes, and belts on a cooling tower at Melbourne University. Completed in 2025, the work required meticulous planning, safety compliance, and precise execution to ensure optimal operation of the cooling system while minimising downtime.

Project Details:

Client

AG Coombs Servicing P/L

Project Status

Complete

Job Type

Installation of new fan motor, bearings, shaft, pulleys, bushes and belts

Year Completed

2025

Project Overview

The Workflow: From Arrival to Completion

The team’s journey began with proper site preparation:

Site Arrival & Permits: The crew logged their arrival on-site, completed all necessary permits, and conducted Job Safety Analyses (JSA) to ensure a safe working environment.
Material Loading: Essential materials and tools were loaded onto site, ready for the installation process.

Once prepared, the team proceeded with the critical steps of disconnection and removal:

Isolation & Disconnection: The cooling tower was isolated, and the old fan motor was disconnected. The access hatch was removed to facilitate component removal.
Component Removal: The old fan, motor, pulleys, fan shaft, and bearings were carefully removed. Grease lines were disconnected to allow for complete disassembly.

The installation phase involved precise replacement and assembly:

Installation of New Components: New bearings and the fan shaft were installed, with new grease lines reconnected. The old fan was removed, and the new fan was installed onto the shaft.
Motor & Pulleys: The old fan motor was disposed of off-site, and a new motor was installed. Pulleys for the fan and motor were fitted, with anti-seize applied to all new parts to ensure smooth operation.
Belt Tensioning: New fan belts were installed and properly tensioned to optimise performance.

Post-installation testing was crucial:

Electrical & Operational Testing: The site contact wired the new motor, and comprehensive testing confirmed the fan operated correctly, ensuring system reliability.

Finally, the project concluded with site cleanup and safety procedures:

Site Closure: The access hatch was re-closed, the cooling tower was de-isolated, and all equipment was packed up. Permits and JSA documentation were closed out, marking the end of the project.

Project Success

FlowMatrix played a vital role throughout this project by:

Providing real-time updates on each task’s status, ensuring transparency.
Allowing team members to upload photos and documentation at each stage, creating an accurate record.
Attaching and verifying all permits, JSAs, and safety checklists to maintain compliance.
Confirming task completion with verified checklists, ensuring safety and quality standards.
Generating detailed reports and analytics post-project, helping identify lessons learned and areas for improvement.

The Melbourne University project showcases the modern approach of repair & rebuild services – FlowMatrix can enhance safety, efficiency, and accountability in complex maintenance and installation tasks. By integrating real-time tracking, comprehensive documentation, and seamless communication, companies can deliver high-quality results while maintaining safety standards and meeting client expectations.

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