Project Overview

During Refueling Outage 3R25, Bunney’s Inc. provided specialized fabrication, structural replacement, and fan assembly services for the cooling towers at the Palo Verde Generating Station.

This work supports ongoing maintenance and reliability improvements across APS’s power-generation infrastructure and demonstrates Bunney’s ability to perform high-precision work during tight outage schedules.

Scope of Work

• Fabrication, delivery, and installation of new concrete support beams for the cooling towers.
• Removal and replacement of degraded beam structures, decking, and connection points.
• Assembly and installation of new fan assemblies, including crane operations, rigging the fans for placement.
• Close coordination with APS engineering, the outage project team, and safety teams to ensure schedule alignment and compliance with nuclear-site protocols.

Challenges & Solutions

Executing this work during a refueling outage presented unique challenges, including a compressed schedule, limited access within an active cooling system, and the need to safely remove deteriorated structural components. Bunney’s Inc. addressed these challenges through advanced planning, offsite prefabrication, and precise coordination with APS operations and safety personnel. Custom rigging and controlled demolition techniques were used to replace compromised beams safely, while just-in-time material delivery and careful crane scheduling ensured the project stayed on time and fully compliant with outage safety requirements.

Results

Bunney’s Inc. successfully executed all structural and mechanical replacements within the outage window, ensuring reliability and long-term performance of APS’s cooling tower systems. This project highlights Bunney’s proven capability in fabrication, installation, and outage execution for mission-critical power-generation infrastructure.