Cooling Solution Supports Bio-Pharmaceutical Expansion Project in Limerick, Ireland

As with many pharmaceutical and biopharmaceutical projects, long-term operational planning was a critical consideration throughout system design. The project team worked closely with the client and engineering stakeholders to develop a cooling solution capable of supporting efficient operation during both startup and future production expansion phases.

Several important criteria were discussed throughout the project, including:
• Supporting phased production growth through an N+1 cooling strategy
• Maintaining efficient operation during periods of reduced cooling demand
• Supporting effective water management and system circulation to reduce conditions associated with biological risk
• Streamlining installation timelines through preassembly and prewiring activities
• Allowing maintenance flexibility while keeping other cells operational

The project team selected Marley^® NC Cooling Towers to meet the operational and installation requirements for the facility. The supplied towers included the following specifications:

Tower Models:
Phase 1 – 6 Cells NC8413TCS
Phase 2 – 4 Cells NC8413TCS

• Material of Construction: Stainless Steel S304 / Z725 Galvanised Steel
• Fill Pack: 15 Mil PVC Fill
• Fan Type: Ultra Quiet Fan
• Mechanical Configuration: ABB IE4 Electric Motors with Marley Geardrive^® and Motor Inside Airstream (MIA) configuration
• Special Features:
– Multi-cell FM Factory Mutual Approval
– Sweeper piping
– Control panel recess boxes positioned adjacent to access doors
– VFDs, basin level controls, heater controls and vibration monitoring systems

To improve installation efficiency, the cooling towers were initially delivered to CT&A facilities, where components were prewired and tagged prior to shipment. Fans were installed at a holding location before the towers were delivered to the project site. Six towers were lifted into position within a single week, and overall assembly was completed over a three-week period.

The Marley NC Cooling Towers successfully satisfied the facility’s cooling load requirements while also providing long-term operational flexibility and installation efficiencies for the project team. Additional project benefits included:

• Energy Efficiency: The N+1 cooling solution provides a lower-energy operating approach while also helping reduce noise impact during operation.

• Operational Flexibility: The variable-flow capability of the Marley NC allows the facility to gradually increase cooling demand as production expands. The CT&A team liaised with the engineering house to ensure the best approach  to provide effective water circulation during startup and low-load conditions, aligning with water management best practices.

• Efficient Installation: Prewiring, tagging and preassembly activities significantly reduced onsite installation complexity and accelerated project timelines.

• Advanced Monitoring & Controls: CT&A were appointed to supply and carry out the installation, cabling, termination of the VFDs, vibration monitoring, basin level controls and heater control systems provide operators with enhanced system visibility and improved operational reliability.

The collaboration between the client, engineering house, mechanical contractor, and CT&A/SPX Cooling EMEA helped ensure a successful project outcome. The Marley NC Cooling Towers delivered an energy-efficient and flexible cooling solution designed to support the facility’s phased operational growth while providing the long-term reliability expected from Marley products.