New cooling towers
When a tower genuinely has reached the end of its life, we design and build the replacement, and we will tell you honestly when a rebuild or an upgrade would serve you better.
Guaranteed thermal performance, verified independently
A new tower is a thermal design problem before it is a construction problem. We size and model the tower to your duty, then guarantee the performance, and stand behind it under independent testing.
That guarantee is the part worth reading twice. Any supplier will quote a design temperature. We commit to the tower meeting its guaranteed performance level when independently tested, which is a materially different promise, and is the reason we do our own CTI ATC-105 performance testing.
What we design to
- Guaranteed thermal performance at your specified duty and design wet bulb
- Counterflow and crossflow: chosen on the application, not on what we prefer to build
- Computer thermal modeling for optimum fill, distribution and air path
- Minimum fan horsepower for the required duty; this is an operating cost you carry for decades
- Low pumping head: the other half of the parasitic power bill
- Custom and pre-engineered sizes
- Aesthetic considerations where the tower is visible or the site is sensitive
Fan horsepower and pumping head deserve emphasis because they are where a cheap tower becomes an expensive one. The capital difference between an efficient design and an indifferent one is usually recovered within a few years of electricity bills, and then keeps paying for the life of the tower.
New tower erection over completed process piping.
Most towers we are asked to replace do not need replacing. If the structure is sound, a thermal upgrade or a rebuild on the existing basin costs less and takes less time. Ask us to evaluate it first.
Built heavy, built to be maintained
Field-erected towers in timber, concrete, steel or fiberglass. A cooling tower spends its life wet, warm and chemically treated, so the details that matter are the connections, the access and the coatings.
Four structural materials
Rugged heavy-duty construction in wood, concrete, steel or fiberglass. Because we work in all four, the material follows the water chemistry, the fire requirement and the design life, not our preference.
- CTI-grade treated fir and redwood
- Galvanized and coated steel
- Pultruded FRP structure and casing
Thru-bolted framing
Framing is thru-bolted rather than relying on nailed or toe-fixed connections. It is more work to build and it is the difference between a structure that can be repaired member-by-member in twenty years and one that cannot.
- 304 / 316 stainless and monel hardware
- Connections selected for the water chemistry
Constructed for easy maintenance
Access to the fan deck, the distribution system, the mechanical equipment and the basin is designed in. If a gearbox cannot be reached safely, it does not get inspected, and eventually it fails.
- Internal walkways and grating
- Stairways, ladders and cages
- Access doors and view ports
Towers are built to Cooling Technology Institute (CTI) standards for materials and construction, OSHA requirements for access and worker safety, and the International Building Code with the applicable state and local amendments for structural, wind and seismic loading. Gulf Coast wind loading in particular is not a formality.
Field-erected crossflow tower: louvered inlet face, corrugated casing, velocity recovery fan stack and external stair tower.
The awkward jobs are the ones worth calling us for
A straightforward tower on an empty site is something many contractors can build. These are the situations where specialist experience actually changes the outcome.
- New towers built on existing basins: keeps the basin, foundations and piping you already paid for
- On-line replacement: dismantle and rebuild one cell at a time, so the plant keeps running
- Crossflow to counterflow conversion where the application justifies it
- Close approach to wet bulb temperatures
- High hot water temperatures and low wet bulbs
- High and low pH water: drives material selection throughout
- Severe winter operating conditions
- Seismic considerations
On-line replacement is the one most people have not been offered before. It means a tower replacement does not have to wait for a plant turnaround.
Where people usually go from here
Inspections & engineering
Find out whether you need a new tower at all. A written evaluation covers structure, thermal performance and safety of operation.
View serviceRepairs & upgrades
The cheaper answer in most cases: modern internals in the structure you already own, or a rebuild on the existing basin.
View serviceCapabilities
On-line replacement, difficult water chemistry, freeze service, seismic design and all four structural materials.
View capabilitiesSend us your duty and your design wet bulb
Flow rate, hot and cold water temperatures, design wet bulb and the space you have to work in. That is enough for us to tell you what the tower needs to be, and whether you need a new one.
- Phone
- (713) 643-0691
- Shop & office
-
3811 Cedar Blvd Ste A
Baytown, TX 77523