Industrial Cooling


Centrica’s South Humber Bank Power Plant
The Problem

In February 2014, DHD Cooling was contacted by Centrica’s South Humber Bank Power Plant in the North East of England. The plant was suffering sensitive equipment freezing during harsh weather as a result of being situated on an estuary. . This resulted in the immediate shutdown of the boilers and terminated production at the plant. The shutdowns were cost hundreds of thousands of pounds in lost generation each winter.

The Consultation

In conjunction with our partners Galebreaker Industrial, DHD Cooling undertook a site survey and consultation to identify the cause and extent of the freezing issue. It was found that the majority of the sensors that were freezing were outside of the area of the existing cladding, on the West face of the Heat Recovery Steam Generator (HRSG). This meant that the sensors were also directly in the path of the strong winds coming in from the North Sea. The client had already attempted to protect each of the sensors, with localised covers, but the wind chill was so great that they were ineffective.

The Solution

DHD Cooling and Galebreaker Industrial put together a scope of works to situate bespoke tensioned fabric Wind Shields across strategic locations to nullify the effects of the wind on the sensitive equipment. Galebreaker’s PVC coated polyester windshields are designed to withstand wind speeds of up to 90mph, and the partially permeable mesh material slows the wind without causing the full wind loadings of conventional cladding.

The simple nature of the ratchet hook connections also meant that additional structural steelwork was kept to a minimum and therefore the installation process was more straightforward than if the client had decided to clad the structure.
Because the windshields were only placed where they were required, the solution offered a significant cost reduction over conventional cladding, and the cost of the system has more than paid for itself as since its installation. The plant has experienced no further shutdowns due to frozen equipment on their HRSG. Since implementation, we have since installed an identical system on the adjacent HRSG.

Key Points

  • Cost effective, bespoke weather protection system.
  • Easy and fast installation.
  • Minimal additional steelwork required.
  • ROI after first winter.



air cooler exterior

Air cooled equipment uses ambient air to cool a process or system by transferring the heat across a very efficient heat transfer surface into the surrounding environment, simple and effective.

Typically the medium used to cool the system or process will be water mixed with an antifreeze to prevent freezing in the colder months, however, in extreme climates where the temperature can fall to -30C and below even the antifreeze additive may not be enough.

The Solution

Using Galebreakers’ compact tube mounted motorised rolling door connected to a temperature probe in the circulating fluid, solid rolling doors automatically deploy to protect the coils from the effects of freezing winds, removing the risk of freezing on your air cooler.

Fitting these automated doors to the unit is a simple case of installing bespoke brackets and runners to the air cooler frame, the final result looked as if it was designed to be there all along including manual overrides in case of power failure.

Suitable for evaporative and dry cooling systems, in both standard and marine grade materials, makes this a simple solution to freezing risk.



Galebreaker rolling filter exterior photo


Cooling systems come in all shapes and sizes, ranging from very small light industrial coolers around the size of a domestic fridge up to cooling systems that are larger than football pitches.

Inlet filtration is designed to trap some of the airborne contamination before it enters your cooling system in an easy to clean location, rather than lodged within the systems themselves, where it is often very difficult to remove debris.

For dry cooling systems the airborne contamination builds up between the fins restricting airflow, but also reducing the effective cooling surface, which leads to lower performance. The delicate nature of the fins generally means that cleaning must be done carefully to ensure that damage does not occur, but it also tends to mean that gentle cleaning of the fins is not always effective, so being able to collect this debris in an easily accessible location means cleaning is easier and more effective, even if it is required a little more frequently.

In the case of evaporative cooling reducing the amount of nutrients that are drawn into the circulating water can help to reduce fouling in the fill pack, or a build-up of contamination in the water system. Less nutrients means less bugs which in turn reduces the chemical demand associated with killing bugs, and less chemicals can prolong the life of the materials of the cooling tower solutions system.

The Cooling Tower Solutions

A facility in Europe installed some cooling tower solutions on their large cooling towers that required filtration on air inlets measuring around 30m long x 3m tall. This was achieved by using a single rolling system across the complete 30m long air inlet face that can be simply manually rolled away for access by a single operative.

The system is attached to the cooling tower structure along the length of the inlet, with the total weight of the equipment being that of the fabric and the rolling bar. Retaining bars are installed at intervals along the length of the screen to contain the screens.

The rolling bar is manually driven using a small hand driven gearbox to allow an operator to roll the entire screen away for access into the cooling system, this arrangement allows costs to be kept to a minimum with a single drive unit being able to serve more than one cell.

This system can very easily be motor driven and even automatically deployed based on a signal, depending on the desired function.

It is possible to deploy this screen during operation, which is a big problem with loose screen options, and changeover of the screens for any reason requires the minimum of time as the screens can simply be slipped out of the retainers and replaced, which is a 20 minute operation.



evaporative cooling tower
Evaporative cooling towers reject heat into the atmosphere in the form of warm saturated wet air, the larger the heat rejection the more water will be rejected into the environment, and in the right conditions this water vapour will form visible clouds above the cooling towers. Think of it as nothing more than when you breathe out on a cold day, the moisture in your breath cannot be absorbed by the cold air outside of your body quickly enough, so water droplets are formed, which reflect light creating visible plume.

On a large scale this can cause safety concerns, where these plume clouds can ground near equipment or on roads and foot paths creating wet and potentially icy surfaces. It can also obscure visibility which can be an issue on roads or around airports, or in some cases people just don’t like the look of it and associate these fluffy white clouds of pure evaporated water vapour, with pollution.

Whatever the reason, a greater degree of plume control can be achieved by installing air side dampers, which can vary the airflow into a cooling tower reducing plume formation or increasing performance.

The Solution

Using manually operated rolling doors to vary the airflow into the cooling towers, it is possible to increase the plume abatement effect of the cooling towers seasonally, so that maximum plume abatement is achieved in the winter and maximum evaporative performance is achieved in the summer.

Installation of the system is simple requiring a couple of side channels and brackets to be fitted to the equipment, for the screens to attach to and where they will travel up and down the face of the equipment.

Each screen is designed to fit onto the equipment to completely cover the air inlet, providing a full protective screen which can be fitted with easily interchangeable winter protection, airside control or air inlet filtration screens.

This system can be scaled up and automated, varying the position of the air side dampers to maximise performance.

For plume abated cooling towers cold water temperatures can be reduced by more than 1ºC leading to increased generating capacity or improved plant performance in the summer months.

Please find more information on our website here.



large airborne particulate filter close up

The Problem

DHD Cooling were contacted in September 2019 by a plastics manufacturer who has two Cooling Towers running with belt-driven fans. The issue being that the bearing housings that the fan shaft was connected to were failing on a regular basis, causing plant outages and lost production. The client had a shutdown in October and wanted the situation resolved during this time.

The Consultation

The client had the idea that a gearbox driven fan would be a better solution, and DHD’s advice was requested on the possibility to retrofit a solution into the Cooling Towers. DHD used Solid Works software and build a model of the Cooling Tower to explore the options. After a week of consultation with the client a solution was found with components that could be delivered in time for the shutdown window. 

The Solution

It was possible to remove the top section of the Cooling Tower which contained the belt-drive and pulley system. This was lowered to ground-level and was installed onto a work platform to ensure the refurbishment could be carried out safely. The externally mounted motor which was installed vertically for the belt-drive was removed from the Cooling Tower along with its support hardware.

DHD designed a new ring-beam support structure and external motor support and had this independently structurally assessed to ensure it would withstand both the weight of the installed components and be free from resonance when the gearbox was in operation. 

With the belt-drive and pulley removed from the top of the Cooling Tower, this section was then lifted onto the ring-beam and bolted down, all at ground level. The new Gearbox was installed onto the ring-beam, and the fan installed onto the Gearbox. The motor removed from the Cooling Tower previously was then installed onto the side-support platform.

This assembly was then lifted back onto the Cooling Tower Fill section and bolted down. A new fibre-glass driveshaft was installed between the gearbox and motor and these components were aligned to ensure proper running.


ICS Cool Energy Grows its Fleet with Customised “Ready to Hire” Process Chillers and Air Handling Units


ICS Cool Energy, an international market leader specialising in complete temperature control solutions for manufacturing process and facilities applications, announced today it is increasing investment in its hire fleet and ads close to 150 new “Ready-to-Hire” solutions including i-Chillers and Air Handling Units (AHU). The new units benefit from the close collaboration between the engineering teams of ICS Cool Energy and the original equipment manufacturers MTA and AL-KO Air Technology.

“MTA and AL-KO were recently acquired by Trane Technologies and are part of the organization’s Commercial HVAC portfolio,” said Dave Palmer, general manager for UK at ICS Cool Energy. “As members of the same family, our engineering teams could work closer together to customise the proven equipment and tailor it to the specific requirements of hire projects. These new “Ready-to-Hire” units are now available in ICS Cool Energy rental fleet.”

Ready-to-Hire Air Handling Units

Collaboration with AL-KO Air Technology, a German expert in ventilation and air handling systems that are customized and manufactured for their application, resulted with new AHU solutions in
ICS Cool Energy’s hire offering. Quality and reliability are the decisive factors for ventilation technology in the industrial sector and the new 150kW air handling units offer tight temperature control, which directly translates into energy saving potential from the chiller or heaters within the system. Compared with the older constant-speed systems, the new AHUs feature new controls managing the fan speed and a 3-way valve system for more precise supply of hot or cold water, adapting the operations of the AHU to the desired room temperature.

The new AHUs were designed by the ICS Cool Energy and AL-KO teams as a plug-and-play solution to fit any customer application. The units can also be connected to heat pumps, switching it into cooling or heating mode depending on the ambient temperature or the temperature set point for maximised energy savings and with no interaction requirement from the customer.

Ready-to-Hire i-Chillers

The ICS Cool Energy hire fleet will grow this year with close to 150 new i-Chillers, heat pumps and low-temperature units reaching -25°C, all designed to cope with the rigours of manufacturing and critical processes. These units are suitable for all types of process applications including Food & Beverage, Plastics, Chemical & Pharmaceutical, Metal Works and other demanding.

Unlike other units on the market, the i-Chiller range has been designed with process applications in mind from the ground up. As such they can operate faultlessly and maintain accurate temperature control 24/7 under highly differing, and abruptly fluctuating operating conditions.

Now, together with MTA, an Italian-based manufacturer and distributor of sustainable solutions in industrial process cooling, air conditioning and air treatment, ICS Cool Energy customised the “Ready-to-Hire” units to be even more robust and flexible in transport and customer installation.

“We worked closely with the MTA team, exploring the pain points of hire-destined units and have come up with installation features and solutions so our customers can benefit from the technology quicker and with improved efficiency,” said Jason Lamley, technical manager at ICS Cool Energy. “These 150 new hire chillers are manufactured specifically for ICS Cool Energy, are specified and finalised directly in the factory and can be shipped straight to the customer for installation, significantly speeding up the entire process.”

ICS Cool Energy solutions are available for short or long-term hire, as well as part of the FLEX Membership, long-term exchange programme. FLEX Membership subscription offering gives customers access to the latest process heating and cooling equipment with the flexibility of an operating expense. As part of the flexible package customers receive the equipment, preventive and 24/7 emergency maintenance, replacements and upgrades for an all-inclusive monthly rate. This allows them to transform their process temperature control system from a fixed asset into a dynamic solution that will be up-to-date with their changing business and process needs.

For more information on ICS Cool Energy complete process temperature control solutions, please visit

ICS Cool Energy Introduces ICS Protect Agreements,

New Service Programmes for Temperature Control Equipment

The new ICS Protect service packages offer customers a tailored, cost-efficient approach to their maintenance needs with different preventive and predictive coverage levels.

 ICS Cool Energy, an international market leader specializing in complete temperature control solutions for manufacturing process and facilities applications, introduced ICS Protect Agreements, new extended and enhanced service plans offering for its i-Chiller range and other temperature control equipment.

The new ICS Protect Agreements offer three levels of coverage including preventive maintenance plans, delivering partial to fully comprehensive solutions. This approach allows customers to choose a package that is tailored to their applications and business needs, and ensure the temperature control equipment receives regular inspection, preventive maintenance, and proper calibration minimising the risks of equipment failures.

 The longer the plan, the better the saving potential and reduction of downtime.  In the case of the i-Chiller range of process-designed chillers, the ICS Protect offers customers the option to continue protecting their investment beyond the market leading 5-year parts and labour warranty coverage.

“Facility managers understand their organisation’s dependence on the process temperature control systems to ensure continued manufacturing and business operations. Equipment that is improperly maintained can fail to provide the required level of efficiency,” said Dave Palmer, general manager of ICS Cool Energy in the UK and Ireland.

“We have designed the ICS Protect Agreements to provide our customers with operating efficiency, prolong their system’s life and simply help them cut costs. Keeping the equipment in optimal shape minimises the energy consumption, helps limit downtime and eliminate operating losses. These are critical factors that all manufacturers pay attention to, and with ICS Protect Agreements we can ensure the constant performance of the equipment with no hassle for the customer,” continued Palmer.  

With ICS Protect Agreements customers can choose their level of coverage from Bronze, Silver and Gold packages offering different configurations of Individual Parts, All Parts, and Parts and Labour.  Every level comes with complete market leading preventative maintenance visits (two per annum) and individual asset fluid analysis.

“With an ICS Protect Agreement, besides gaining priority response, proactive maintenance and parts coverage, our customers can decrease their administration-related expenses as well as in-house labour and outside maintenance expenses to save up to 25% in operating costs. The longer the agreement term, the larger the savings, leaving it up to ICS Cool Energy to support the aging equipment,” concluded Palmer.

The ICS Protect agreement covers equipment up to 10 years of age.

ICS Cool Energy is headquartered in Southampton within 100,000 square feet of warehouse, office and yard space facilitating new stock storage and engineering spaces for service operations. The central location is backed up by the depot in Bradford and regional offices in London, Birmingham, Glasgow and Dublin, as well as by over 70 mobile service engineers with van stock, to ensure customer support and service across the U.K and Ireland.

For more information on ICS Cool Energy complete process temperature control solutions, please visit


Gary Dicker, director at dhd cooling, explains why the evaporative cooling tower is still a great choice.

There is a lot of bad press surrounding evaporative cooling towers, but they are still one of the best long-term solutions for industrial and commercial cooling challenges and here’s why.

In order to reach certain cooling temperatures dry cooling alone is not the answer, in these cases there are a few bolt-on options that you can put on a dry cooler that will reduce cold water temperatures, but these come with their own distinct disadvantages.


DHD Cooling, working with Galebreaker, is constantly expanding its range of wind and weather protection systems to meet the many challenges in the power and industrial sectors.

As the market leader in weather protection systems Galebreaker continues to develop CFD modelling techniques that can accurately model entire air cooled power plants to determine the right position and porosity of wind reduction systems. These solutions have not only improved thermal efficiency of power plants but also protect mechanical equipment from wind induced vibrations, so reducing downtime and improving mechanical performance.

Airborne Water Droplets Are a Big Issue, if You Catch My Drift


Drift from a cooling tower can be a huge problem. Drift is the aerosol emission of process water from a cooling tower. These emissions are capable of travelling upwards of 1km, with a properly treated system the level of bacteria must be controlled within safe parameters but even in these systems the water droplets could be carrying Legionella Bacteria, so the potential for an outbreak is increased, if more drift is created. This is why it is critically important that as a plant operator you can spot the signs of excessive drift, and do something about it before it becomes a problem.

Cooling Tower Safety and Maintenance The Importance of Aligning Debris Management With Water Treatment Procedures By Randy Simmons

The following is an important reminder of the need for all companies and institutions utilizing cooling towers, to adopt diligent maintenance and water treatment programs; Why? - Because what's at stake is worker health & safety, operational efficiency and the company's reputation. In recent years a major worldwide auto manufacturer experienced a tragedy when four of its maintenance workers became ill with pneumonia-like symptoms that ultimately claimed the lives of two. The cause - Legionnaires Disease due to Legionella bacteria found in one of the manufacturers cooling towers.

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