Cooling Tower Fill Replacement

Orica’s cooling tower at the Kooragang Island facility required a full fill replacement to maintain thermal efficiency and structural integrity. The challenge was to complete the work within a tight shutdown window, coordinating with multiple contractors and ensuring zero disruption to plant operations.

Marley Flow Control executed a precision-based strategy to meet the shutdown deadline:

• Fill Removal & Replacement:
   

  • Removed aging fill material from the tower’s wetted zone

  • Installed new Marley polypropylene splash fill bars and FRP grids for improved thermal performance

• Structural Timber Repairs:
   

  • Replaced compromised timber within the wetted zone to restore integrity and support

• Mechanical Overhaul:
   

  • Removed and reinstalled mechanical components including motor, driveshaft, gearbox, and fan

  • Conducted laser alignment to ensure optimal performance

• Hardware Upgrades:
   

  • Replaced all bolts and anchor brackets in the wetted zone

• Execution Methodology:
   

  • Fill removed bottom-up for safe access

  • New fill installed top-down to ensure alignment and airflow consistency

  • All works completed in accordance with contract specifications and safety protocols

This project demonstrated Marley Flow Control’s ability to deliver high-performance cooling tower upgrades under time-sensitive conditions, with precision and safety at the forefront.

​

• Completed Within Shutdown Window

• Zero Safety Incidents

• Improved Cooling Efficiency

• Restored Structural Integrity