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PVC Plant Freeport, Texas

Project: Shintech Tower Replacement

Industry: Chemical

Location: Freeport, TX

Tower: 3-Cell, Wood Crossflow to Counterflow Fiberglass FRP Conversion

Year: 2015

Counterflow to Crossflow Conversion: Working closely with the owner, ICS demolished an existing and failing Marley 3-cell, wood, crossflow cooling tower and installed a new ICS FRP counter-flow cooling tower with higher capacity in the existing basin. The new tower was up and operating within 22 days to fit within a critical plant outage. ICS closely coordinated with the customer to make certain all project concerns were addressed professionally and to the customer’s satisfaction before mobilization. then perfectly executed upon mobilization. Safety was a major concern of the customer and ICS met and exceeded all expectations with a zero incident completion. ICS is committed to safety in all aspects of our business.

ICS provides our customers with high performance cooling towers designed to meet or exceed project requirements. This crossflow to counterflow conversion required perfect execution in a tight schedule. ICS worked with the engineering team, maintenance and operations team closely to ensure we understood and worked well with the plant rules and requirements yet still completed a complex schedule on time. Ask ICS how we can help you complete your most complex projects safely, on time and on budget.

ICS has completed many crossflow to counterflow conversions with splash to film fill conversions and performance upgrades. Call or email to learn more. ICS works within the existing basin and maximizes performance by optimizing design and materials selections to ensure the right cooling tower for the project and at the right price. Ask how ICS can improve your plant performance by providing more cold water in the same existing basin giving you a quick return on investment (ROI). Marley, GEA, PSI, Hamon, Fluor or other brands, ICS has the expertise to upgrade your cooling tower to gain maximum performance and minimize total cooling tower power savings.

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BacMan 1 & 2

ICS performed complete “splash fill” to “film fill” conversions and total tower rehabilitation (structure, mechanical, decking) under a tight time schedule and with a perfect safety record for two counterflow, wood, six-cell towers.

Project: BacMan 3

Industry: Geothermal

Location: Philippines

Tower Type
: 6-Cell, Counterflow, Wood

Client: EDC

Year: 2011

Cooling Tower Rehabilitation with Splash to Film Fill Conversion:
ICS was hired to help EDC Philippines with a major upgrade of an old geothermal power station. Two 6-cell Hamon wooden structure splash fill cooling towers were in bad shape and in need of serious repair. EDC also wanted to maximize backpressure on the turbine. ICS offered and guaranteed substantial cooling tower performance upgrades which would help. ICS was selected to do an extensive rehabilitation and thermal upgrade of the towers on a very tight budget. ICS replaced more than 70% of the structure & mechanical equipment but reused what was possible to save cost. Splash fill was removed and a low-fouling film fill was installed. The reduced pumphead from the splash to film conversion saves EDC power consumption everyday. The added performance allowed EDC to greatly improve plant performance. ICS completed our works on schedule and was the first contractor to complete works in this very remote and difficult site.

Ask ICS how we can support your cooling tower rehabilitation projects splash to film fill conversions, structural upgrades, mechanical upgrades and overall thermal upgrades to your project.

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Cooling Tower Disaster Recovery

Project: Cooling Tower Disaster Recovery

Tower Type: Counterflow, Wood

Location: Philippines

Client: EDC


When the Leyte typhoon destroyed Malitbog and the cooling towers, Energy Development Corp (EDC) needed help fast. ICS was first on the ground in the Philippines to provide emergency assistance by surveying damage and supporting rehabilitation for three power plants with multiple towers.

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Mak Ban 6

Turnkey Upgrade and Rehabilitation of old SPX Marley Crossflow cooling tower

Project: Mak Ban 6

Tower Type: 6-Cell, Crossflow, Wood.

Location: Luzon, Philippines

Year: 2008

Major repair project of a dilapidated 6-cell crossflow wood cooling tower. Aboitiz Power hired ICS to help Aboitiz rehabilitate an an old SPX Marley crossflow tower to peak performance and make it reliable again. The project was made much more difficult by the advanced state of decay of the wood, necessitating ICS and our local partner to have stringent safety protocols to ensure a Zero incident project. Starting from the top, ICS replaced most of the fan and hot water decks and the joists deck joists, the fans were rebuilt, gearboxes and driveshafts as well. Fill was replaced as needed and rehung as practical as were the drift eliminators. – total turnkey engineering, supply and construction by ICS.

Have an old dilapidated tower or just an under performing cooling tower in need of specialized attention and care? ICS can help you analyze, pre-plan and budget your work and take the project from planning to successful completion. Contact ICS now to ask how we can help you upgrade your plant performance.
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