Unilever Australia North Rocks — Rooftop Cooling Tower Replacement
Design and construction replacement of 2 off rooftop cooling towers serving the chiller plant at the Unilever Australia HPC Manufacturing Plant, North Rocks, including a new condenser water pump, sidestream filtration, structural access platform, chemical dosing system, and new condenser water pipework.
Project story
QEG was engaged by Unilever Australia Trading Ltd to replace two ageing rooftop cooling towers at the North Rocks HPC Manufacturing Plant with high-efficiency Shinwa SDC-U100ASD cross-flow cooling towers, each rated at 437 kW heat rejection capacity. The scope included full engineering design, structural and hydraulic calculations, fabrication and supply of a galvanised structural access platform, removal and crane-lift disposal of the redundant units, supply and installation of new condenser water pipework, and commissioning of the replacement towers. A new 15 kW Baker Bloc BB100-26 condenser water pump was added under variation following an NPSH analysis which identified a shortfall with the existing pump at the required operating conditions. Sidestream filtration and a Zetol chemical dosing skid were also incorporated to maintain condenser water quality and protect the replacement tower fill and chiller condensers.
Equipment installed
- 2 x Shinwa SDC-U100ASD cross-flow cooling towers, 437 kW heat rejection each, 1140 L/min flow rate, 2.2 kW belt-drive fan motor, FRP casing
- 1 x Baker Bloc BB100-26 condenser water pump, 15 kW, 38 L/s at 21 m head, stainless steel impeller, IP55
- 1 x Sidestream filtration (SSF) unit — Integra Multicyclone 16 pattern
- 1 x Zetol BCD25 chemical dosing skid, 2-channel rack with circulating pump
- Galvanised structural access platform with FRP grating, fabricated by Lepol Steel
- New condenser water pipework (supply and return from pump to cooling towers)
Photography