Upgrade & Optimisation

Higher capacity. Lower plume. Quieter operation.

Thermal performance upgrades and hybrid conversions for existing cooling towers — design, supply and installation, independent of any single OEM. In-house technical capability is rare outside the equipment manufacturers themselves.

3 outcome areas
Design to commissioning
OEM-independent
Overview

Engineering changes that pay back on existing plant.

) (cps provide technical support for thermal calculations behind capacity upgrades and hybrid conversions for plume control on existing cooling towers. We offer full system design, supply of ancillary equipment, and a demolition and installation service where retrofit is required.

This combination of design capability, manufacturer-independent advice and direct installation experience is uncommon outside the original OEM channel. For thermal-related issues, system design, cooling plant layout or environmental impact, see our consultancy service.

Scope
Design to install

Thermal modelling, system design, supply, demolition and installation.

Outcomes
Capacity, plume, noise

Three primary upgrade outcomes, often combined in a single retrofit.

Approach
OEM-independent

In-house expertise normally only available from the original manufacturer.

Reach
Any manufacturer

Existing plant of any age, make or material of construction.

Three upgrade outcomes

03  commonly combined
01 / Capacity

Higher thermal capacity

Increase cooling duty on existing towers without civil-engineering replacement — through fill, distribution and drive upgrades matched to the operating envelope.

  • High-efficiency fill upgrade
  • Distribution system replacement
  • Fan and drive optimisation
  • Process load matching
02 / Plume

Plume reduction & hybrid conversion

Cut visible plume on planning-sensitive sites by converting wet towers to hybrid wet-dry operation — mixing saturated air with bypass dry air to lower exit humidity.

  • Hybrid wet-dry conversion
  • Dry coil retrofit
  • Plume abatement planning consent
  • Winter operation modelling
03 / Efficiency

Energy & noise efficiency

Reduce fan motor energy and operational noise — through fan and gearbox replacement, low-noise stack design, and variable-speed drive integration where suitable.

  • Low-noise fan stacks
  • VSD drive integration
  • Acoustic attenuation
  • Energy consumption modelling
Project process

From thermal modelling to commissioning.

01

Assess

Site survey and current performance assessment — what the plant is doing today versus what's possible.

02

Design

Thermal calculations and engineered upgrade scope — fill, distribution, drives, hybrid stages where required.

03

Specify

Detailed specification of materials, components and ancillary equipment — costed and scheduled.

04

Install

Demolition of redundant elements and installation of new — managed around your shutdown window.

05

Verify

Commissioning and post-installation performance verification — proving the upgrade against the design intent.

/ Sub-service

In-house consultancy on all water-cooling matters.

) (cps have in-house expertise to provide a consultancy service related to every aspect of water cooling towers and their application — from initial concept and system design through to operational troubleshooting and environmental compliance.

Consultancy service
  • 01 System design & plant layout
  • 02 Thermal performance issues
  • 03 Environmental impact assessment
  • 04 Operational troubleshooting

Sectors served

Existing plant, every industry
01 Power generation
02 Petrochemicals & refining
03 Process industry
04 Building services & HVAC
05 Data centres
06 Food production
07 Pharmaceutical
08 District heating & cooling
09 Manufacturing

Also see

Got an underperforming tower?

Call +44 (0)1535 273 580 or share your site data — we'll model what's possible.