Project Overview 

Piramal Healthcare, a leading pharmaceutical manufacturer, required an upgrade of its existing cooling tower system at its Morpeth facility. The existing timber cooling towers were ageing, inefficient, and presented significant maintenance challenges. To address these issues, Vistech Cooling Systems Ltd. was commissioned to design and install a modern, efficient, and low-maintenance replacement system. 

Challenges Faced 

  • Aged Infrastructure: The existing timber cooling towers were deteriorating, requiring high maintenance and leading to frequent shutdowns. 
  • Inefficiency: High water and power consumption resulted in increased operational costs. 
  • Safety and Compliance Risks: The porous timber structure fostered bacterial growth, posing a risk of contamination and potential non-compliance with health and safety regulations. 
  • Limited Maintenance Control: Maintenance activities required complete system shutdowns, disrupting production processes. 
  • Site Constraints: The existing cooling tower location posed logistical challenges, necessitating a new placement for improved accessibility and efficiency. 

Vistech’s Solution 

Vistech proposed the installation of four EWK 1260/09 GRP Cooling Towers, designed to improve cooling efficiency, reduce energy consumption, and minimize maintenance requirements. The solution offered key advantages: 

  • Relocated Installation: A new site location was identified to optimise operational efficiency and ease of maintenance. 
  • GRP Construction: Non-corrosive and virtually maintenance-free, eliminating decay and reducing long-term costs. 
  • Enhanced Safety Features: Anti-legionella packing, drift eliminators, and a biocide-impregnated casing to mitigate bacterial growth. 
  • Optimised Performance: The fan motors and pumps operate on inverters, adjusting to temperature and pressure requirements dynamically, improving energy efficiency. 
  • Operational Continuity: The four-tower configuration allows for staggered maintenance without process shutdowns, ensuring uninterrupted operations. 
  • Remote Monitoring: Integrated control systems enable real-time performance tracking and remote monitoring, reducing manual intervention and improving efficiency. 
  • Custom-Designed Infrastructure: Vistech engineered and installed the necessary civils, steel structural supports, pipework, and controls to ensure seamless integration with existing processes. 

Implementation 

The project was executed with minimal disruption to Piramal’s operations. Key aspects of the implementation included: 

  • Site Selection & Preparation: A new location was identified to improve system performance and maintainability, followed by structural assessments, civil works, and ground surveys. 
  • Installation: Assembly and commissioning of the new cooling towers, including steelwork support structures, access platforms, and a GRP enclosure for control systems. 
  • Integration with Existing Systems: Extensive engineering was undertaken to design and install pipework and control systems connecting the cooling towers to Piramal’s processes. 
  • Remote Monitoring Deployment: The system was equipped with remote monitoring capabilities, allowing for proactive maintenance and performance optimization. 
  • Testing and Commissioning: Performance validation was conducted to verify cooling efficiency and system reliability. 

Project Outcomes 

  • Increased Cooling Efficiency: The system achieved a total heat rejection capacity of 2,103.6 kW, meeting Piramal’s cooling demands effectively. 
  • Cost Savings: Optimised energy usage resulted in reduced operational expenses. 
  • Regulatory Compliance: The new system meets stringent safety and environmental standards. 
  • Enhanced Reliability: The robust design, advanced control systems, and remote monitoring capabilities have significantly reduced maintenance downtime. 
  • Future-Proofing: The new infrastructure supports future expansion and upgrades, ensuring long-term operational benefits. 

Client Feedback 

Piramal Healthcare expressed high satisfaction with the results, noting significant improvements in cooling performance, operational efficiency, and system reliability. The project underscored Vistech’s expertise in delivering tailored cooling solutions that align with client needs and industry best practices. 

“The system has been designed so any one of the 4 cooling towers can be shut down for maintenance or cleaning and the remaining 3 towers can supply the full required duty. 
Big thank you to our Piramal Engineering teams together with Vistech Cooling Systems in delivering a state of the art, energy efficient £1.5M investment. Also thanks to SUEZ UK for delivering the Chemical dosing system.” 

Conclusion 

The successful completion of the cooling tower upgrade at Piramal Healthcare demonstrates Vistech Cooling Systems Ltd.’s ability to implement innovative, high-efficiency solutions for industrial cooling challenges. The project highlights the benefits of modern cooling tower technology in improving sustainability, cost efficiency, and operational continuity while leveraging remote monitoring and custom-designed infrastructure for superior performance.