Shell Industrial Cooling Tower Rebuild

A routine inspection completed by Shell in 2005 discovered severe structural damage in their Class 600, 8-cell cooling tower. The timber throughout the structure was severely compromised, potentially posing a serious risk to the safety of workers and operational tasks alike. Due to the nature of the refinery, a full rebuild, which was initially recommended was unable to be completed. This meant that Shell required a solution that would not disrupt operations and would restore the tower’s integrity to its previous state.  

Marley Flow Control was required to inspect and ultimately rebuild the cooling tower. The project was awarded via tender in March 2006. Due to manufacturing and operational constraints, only one cell could be taken offline at a time, and only during winter months, resulting in a phased rebuild over four years.

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Key execution strategies included:

• Bottom-Up Timber Replacement: Entering from the base and replacing timber progressively upward to ensure safe working platforms

• Structural Rebuild: Replacing all compromised timber to restore full integrity across all eight cells

• Fill Installation: Installed top-down using Marley’s standard splash bar alignment method for optimal airflow

• Material Selection: “V bar” fill chosen for its cost-effectiveness, ease of installation, and performance suitability

• Eliminator & Fan Deck Replacement: Installed new eliminators and replaced severely damaged fan decks due to wet rot

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Throughout the rebuild, Marley maintained strict safety protocols and coordinated closely with Shell to ensure zero disruption to refinery operations.

The project is regarded by Marley Flow as one of its most significant success stories, given the initial condition of the tower and the complexity of the rebuild.

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• Structural Integrity Fully Restored

• Improved Cooling Performance: Colder water returned to the process, enhancing plant efficiency

• Zero Lost-Time Injuries over the four-year rebuild

• On-Time Completion despite seasonal and operational constraints