The Worsley Alumina Powerhouse faced recurring issues with potable water lines, resulting in damage to critical equipment, including chillers, hot water systems, and sample coolers. Corrosion in the system led to failures in stainless steel and copper components, affecting operational reliability.
- Location: Davenport (WA)
- Industry: Commercial
Challenges:
The powerhouse experienced significant issues with corrosion in the potable water lines due to water treatment dosing problems, which damaged stainless steel and copper components in the cooling bath and heat exchanger. This corrosion caused the ZIP heater and several hot water systems to fail. The existing chiller system was outdated and not capable of maintaining consistent cooling flow rates, while the compact cabinet design restricted access, making maintenance difficult and inefficient.
Our Process:
Replacement of Chiller System: A new Clivet WRH142 Chiller was installed, offering a two-stage configuration for redundancy.
Improved Access and Layout: The new unit’s components are spread out vertically, creating more space for maintenance.
Simplified Controls: Upgraded controls to a Carel-style system for improved ease of use.
Flexible Cooling Rates: The new chiller system was designed to allow varying cooling flow rates for improved temperature regulation.
Additional Installation: A Fluid Chillers Australia unit was installed outside the room due to space constraints, providing a compact and simple solution with readily available components.
Outcome
- Improved reliability and reduced maintenance requirements.
- Enhanced access for servicing and repairs.
- Consistent cooling performance across sample lines.
- Simplified control system, improving ease of operation.
- Reduced risk of future corrosion through improved water treatment practices.
Need a tailored solution for your cooling system challenges? Contact Masterflow today to find out how we can enhance your system’s performance and reliability.