CS Energy Industrial Cooling Tower Repair

During the 2019 shutdown of Callide Power Station Unit C, CS Energy required a full fan deck replacement on one of the largest cooling towers in the southern hemisphere. The project had to be completed within a compressed three-week window, while coordinating with multiple contractors operating simultaneously across the shutdown site and avoiding any disruption to parallel works already in progress.

Marley Flow Control deployed a precision-engineered methodology designed to meet the aggressive timeline without compromising safety, quality or coordination.

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Pre-Fabrication Strategy

Fan deck components were prefabricated off-site and packed in exact laying order prior to mobilisation. This eliminated the need for on-site cutting within the plenum, significantly improving quality control and installation speed while reducing the risk associated with working in a confined and complex environment.

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Custom Tooling

Bespoke lifting tools were designed specifically for the fan cowling removal and reinstallation. This avoided the need for a 120-tonne crane entirely, simplifying site logistics, reducing cost and removing a significant scheduling dependency from the programme.

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Three-Team Execution Model

To maximise productivity across all 18 cells within the available timeframe, Marley Flow Control deployed three dedicated teams working in a coordinated sequence. The cowling removal team unbolted and lifted the cowling using the in-house designed tools. The deck removal team followed, stripping the deteriorated plywood decking from each cell. The deck installation team then installed the new fibreglass fan deck and replaced damaged timber before the cowling team returned to complete the reinstallation. This process was repeated efficiently and safely across every cell throughout the programme.

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Cross-Contractor Coordination

Works were carefully scheduled around other contractors operating concurrently on the shutdown, including Programmed Maintenance crews cleaning the cold-water basin and MHPS fitters replacing the fire system. Precise coordination ensured there was no interference between teams and that the overall shutdown programme was not impacted.

This project is a clear demonstration of Marley Flow Control's ability to deliver high-stakes industrial repairs under significant time pressure, with precision planning, tooling innovation, disciplined execution and seamless multi-contractor coordination.

• Completed within the three-week shutdown window

• Zero injuries across the full duration of the project

• No disruption to parallel shutdown activities

• Enhanced safety and quality outcomes through pre-fabrication and purpose-built tooling