Client: Battery Processing Plant, Derbyshire, UK
Project Duration: 7 days from tower, pump and pipework installation to commissioning
Overview: Vistech Cooling Systems was contracted by a UK based battery processing plant to provide a turnkey solution for replacing the ageing cooling tower at their facility. Operating in a highly corrosive environment, the plant required a robust solution that could withstand the harsh atmosphere whilst ensuring minimal downtime.
The project involved the full design, delivery, and installation of an EWK 1800/09 cooling tower, stainless steel pump, secondary-side pipework, and GRP access platforms, all delivered and installed during a tight 7-day shutdown period to minimise disruption to plant operations.
Technical Solution: The cooling system delivered a total heat rejection of 6047 kW, designed to meet the plant’s stringent cooling requirements. Key features of the system include:
- GRP Casing and Access Platforms: The cooling tower and platforms were prefabricated using corrosion-resistant GRP, ideal for the battery processing plant’s environment. This material offers long-term durability and significantly reduces maintenance.
- Stainless Steel Pipework: Thin-walled stainless steel pipework was used for quick welding and installation, ensuring efficient system assembly within the limited shutdown window.
- High-Grade Coating: Steelwork was treated with a high-grade anti-corrosive coating to protect against the aggressive atmosphere caused by battery processing activities.
- Energy-Efficient Design: The system was equipped with a 22 kW fan motor with an IE3 efficiency rating, ensuring reduced energy consumption whilst maintaining high performance.
Challenges and Solutions: The plant’s corrosive atmosphere posed a significant challenge, requiring materials and coatings that could endure the harsh conditions. Vistech addressed this by using GRP for the tower and access platforms, known for its exceptional corrosion resistance. The steelwork received a high-grade coating for additional protection, while the stainless-steel pipework offered both strength and corrosion resistance.
The project’s 7-day shutdown period demanded precise planning and coordination to ensure all installations were completed on time. Prefabricated components, including the GRP tower and platforms, allowed for rapid assembly, while the use of thin-walled stainless steel pipework ensured quick and efficient welding onsite.
- Project Management and Implementation: The project was meticulously planned to fit within the 7-day shutdown period:
- Cooling Tower Installation: The prefabricated GRP tower was installed on-site in less than 2 days.
- Pump and Pipework Installation: Stainless steel pipework was quickly welded and installed, connecting the tower to the secondary-side system. This phase was completed in under three days.
- Access Platforms: GRP access platforms were assembled rapidly, ensuring easy and safe access for future maintenance.
Schedule of works completed in 7 days during client shutdown:
Construction of New Tower: Day 1 – 2
Electrical Works: Day 2 – 4
Pipework and Pump Installation: Day 5 – 6
Commissioning: Day 7
Vistech coordinated with external contractors for pipework and electrical modifications whilst our dedicated Site Supervisor managed the entire project to ensure compliance with health and safety standards.
Outcomes and Client Benefits: The new cooling tower provides this battery processing plant with an enhanced heat rejection capacity and improved operational efficiency.
Notable outcomes include:
- System Efficiency: The cooling tower’s energy-efficient design, including its 22 kW fan motor and low-maintenance GRP structure, resulted in significant operational cost savings.
- Corrosion Resistance: The materials and coatings used for the tower, pipework, and steelwork ensure long-term resistance to the plant’s corrosive environment, reducing maintenance and replacement costs.
- Minimal Downtime: The entire system was installed within the 7-day shutdown period, allowing the plant to resume operations on schedule with no delays.
Our client expressed satisfaction with the project’s successful delivery, praising the efficiency of the installation and the high performance of the team working onsite. The quick installation process minimised downtime, and the system’s corrosion resistance will provide long-term reliability.
Client Feedback
Vistech Cooling Systems has a proven track record of delivering similar projects for industrial facilities, including installations for MOD sites and aerospace manufacturers. This experience, combined with certification in ISO 9001, 14001 and 45001, reinforces Vistech’s expertise in designing and delivering high-performance, low-maintenance cooling systems.