Cooling Tower Rescues Steel Manufacturer

Aggreko’s cooling towers rescue steel manufacturer

Aggreko, the world leader in the supply of temporary power and temperature control solutions, has helped a leading steel manufacturer keep its cool following a serious fire at the company’s plant in South Wales.

A 33MW cooling tower at Celsa Manufacturing in Cardiff was destroyed by the fire, which was accidentally started during routine maintenance.  Faced with an immediate loss of production, John Parsons, engineering manager at the Celsa UK melt shop, contacted Aggreko’s National Rental Centre.

Aggreko sales engineer Steve Paskell and service engineer Andrew Jones quickly made an in-depth assessment of the site and with the help of Jan van der Waal, senior process design engineer from Aggreko Process Services (APS), specified the temporary cooling solution for the customer.

By noon the following day, a total of 12 temporary cooling tower modules and ancillary equipment had arrived in Cardiff and the Aggreko team set about ensuring an effective cooling water feed for the plant.   Jan van der Waal and the Aggreko team met up with Celsa’s engineers on site to plan and fine tune the operation.

A major technical and logistical bottleneck of supplying and returning the cooling water from the remaining water pumping system to the Aggreko temporary cooling tower modules was overcome by raising the modules to provide enough height to gravity return the cooling water back into Celsa’s 4.5m high sump.  To achieve this, 36 empty shipping containers were sourced from a local company and the Aggreko temporary cooling tower modules were then assembled on top. This eliminated the need to manufacture large 20ft return pipe runs and shorten the feed to the temporary system, which would have resulted in additional expenditure and even more costly delay for the customer to resume production.

Zaw Hein, Aggreko Process Services explains:  “This was a particularly tricky and technical project where a temporary cooling towers solution was the best option to keep production downtime to a minimum and to get the customer back on line as quickly as possible.

The innovative temporary arrangement Aggreko provided for Celsa demonstrates our technical ability and sheer resourcefulness in finding a solution to the customer’s problem. Our engineers worked through the night to get equipment and factory up and running by 2.00am on Monday”

John Parsons, engineering manager at Celsa Manufacturing, said:  “We have to admit that we thought an effective, temporary cooling tower scenario would be very difficult to achieve at our facility and we were delighted with the speed of response, logistical planning and coordination support received from Aggreko.  We were very impressed not only with the speed of their service, but their technical expertise and inventive approach to solve a very difficult problem.”

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