Restore performance, cut risk, and extend service life
Cooling systems are the quiet workhorses of every generating station. When heat-rejection equipment drifts out of spec, heat rate, output, and reliability follow. Bunney’s Inc. refurbishes cooling towers and auxiliary cooling assets for power producers across Arizona—returning systems to design performance (or better) without the cost and downtime of full replacement.
New to Bunney’s? Learn who we are and explore our capabilities.
What we refurbish (and how)
Mechanical & rotating equipment
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Fan stacks and FRP housings, fan blades, hubs, gearboxes, drives, shafts, bearings
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Motor replacements, VFD upgrades, laser alignment, vibration and balance reports
Hydraulic performance
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Nozzles, headers, and distribution piping re-nozzled/cleaned for uniform spray
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Pump audits: curves, NPSH, seal replacements, impeller trims, soft starts/VFDs
Thermal media & internals
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Film/splash fill replacement (PVC/PP/HP materials), supports, drift eliminators, louvers
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Hot-water basins, weirs, and makeup controls restored to design flow
Basins & structural components
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Concrete repairs (spalls, joint rehab, coatings), corrosion mitigation, cathodic protection
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FRP/steel repairs, fasteners, ladders, platforms, and OSHA-compliant access
Coatings & corrosion control
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Surface prep (CSP profile), industrial linings for immersion/chemical exposure
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Galvanic isolation, hardware upgrades, and protective sealants
Controls, monitoring & safety
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Fan sequencing, freeze and plume controls, smart level sensing, make-up/blowdown logic
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Confined-space, fall protection, and lockout/tagout programs integrated with site protocols
Arizona-tested upgrades that move the needle
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Higher thermal performance: New fill and nozzle layouts reduce approach temperature and restore range.
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Lower parasitic load: VFDs and fan pitch optimization cut kW/ton.
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Water stewardship: Improved drift eliminators, cycles-of-concentration controls, and leak repairs reduce makeup and blowdown.
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Reliability under heat and dust: Materials and cures selected for extreme temperatures, UV, and monsoon exposure.
When it’s time to refurbish (signs to watch)
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Rising condenser backpressure or CT approach temperature
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Uneven water distribution, hot spots, or visible scaling/fouling
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Fan vibration, gearbox noise, frequent seal or bearing failures
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Basin leaks, concrete spalls, or corrosion on framing and supports
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Make-up water and chemical usage trending up without explanation
Our refurbishment process
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Assessment & testing – Thermal walkdowns, flow checks, vibration data, NDE, and water-chem review
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Refurb plan & phasing – Scope, outage/online windows, submittals, and ITPs aligned to operations
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Selective demolition & prep – Safe removal, surface prep, temporary controls and access
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Mechanical & structural rehab – Components replaced/rebuilt; coatings applied to spec
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Controls & optimization – VFD commissioning, sequencing, and alarms integrated with plant DCS
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Performance verification – Balance and alignment reports, torque logs, approach/flow testing, punch-list closeout
Deliverables you can file: submittals, material certs, coating data sheets, torque/vibration/laser-alignment records, inspection photos, and final performance summary.
Compliance & standards
We build to the governing specs for power facilities, including applicable CTI guidance, ACI/ASTM for concrete and materials, and OSHA/fall-protection/permit-required confined space requirements. Site-specific owner standards are integrated into the plan and ITP.
Why power producers choose Bunney’s Inc.
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Outage-friendly execution: Phased work, night shifts, and parallel crews reduce downtime.
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Industrial-only focus: Experienced with baseload, peaker, and combined-cycle stations.
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Quality you can verify: Objective evidence and measurable performance improvements at turnover.
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Arizona experience: Solutions proven in extreme heat, dust, and monsoon conditions.
FAQs
What’s the difference between repair and refurbishment?
Repairs fix single failures. Refurbishment is a coordinated program (mechanical, hydraulic, structural, and controls) that restores system-level performance and reliability.
How much life can refurbishment add?
Typical programs extend useful life 5–15+ years, depending on scope, materials, and water-chemistry management.
Will we need a full outage?
Not always. Many scopes (fan trains, internals, coatings) can be sequenced by cell to keep generation online. We’ll propose outage vs. online phasing with schedule options.
How do you verify improvement?
Before/after data on approach temperature, range, fan power, flows, drift, and vibration—plus alignment and torque logs—are included in closeout.
Can you help reduce water and chemical costs?
Yes. Upgrades to drift eliminators, distribution, leak points, and control logic improve cycles of concentration and lower makeup/blowdown.
What materials perform best in Arizona?
UV-stabilized FRP, high-temp PVC/PP fill, industrial elastomeric/epoxy linings, and corrosion-resistant fasteners selected for heat, UV, and intermittent immersion.
How long does a typical refurbishment take?
Scope-dependent. A single-cell refresh can be days to weeks; multi-cell, full-system programs are phased over several weeks with parallel crews to minimize impact.
Do you provide engineered repairs for concrete?
Yes—ACI-compliant repair designs, joint rehab, coatings, and documentation suitable for audits.
