Cooling Towers refurbished and set by Lyons Mechanical Services and CT/HX

Case Study - Bowling Green Metalforming

Project Details

Operating Companies:

Lyons Mechanical Services,
A Fidelity Company

CT/HX,
A Fidelity Company

Client:
Bowling Green Metalforming (A Magna Company)

Industry: Automotive

Category: Service/Refurbish

Gross Square Footage: 1,168,259

Bowling Green Metalforming (A Magna Company), a global automotive supplier to the Original Equipment Manufacturer (OEM) market, retained Lyons Mechanical Services (A Fidelity Company), a provider of comprehensive HVAC/Mechanical solutions, to refurbish four existing cooling towers at their facility to improve their overall operating efficiency and longevity. 

A division of Cosma Canada/USA and operating unit of Magna International, Bowling Green Metalforming supports companies like Ford Motor Co. in Louisville, Kentucky with a focus on fabricated metal products, aerosol valves, and truck trailer chassis.

Objectives

This project aimed to enhance the operational efficiency and prolong the lifespan of four existing cooling towers situated at the Bowling Green Metalforming facility in Northern Warren County, Kentucky. Crucial to various sectors including chemical processing, steel production, and manufacturing, industrial cooling towers play a vital role in process cooling by extracting heat from water through the evaporation of a small portion of the water which is then recirculated through the unit. 

Seeking to lower operating costs, Bowling Green Metalforming opted to refurbish the existing towers instead of replacement. Work was meant to be completed without any disruption to manufacturing operations. 

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Solutions

After a conversation with Bowling Green Metalforming, Lyons collaborated with a Fidelity Building Services Group (Fidelity) partner company, CT/HX, a nationwide specialty provider of cooling tower and heat exchanger overhaul services. CT/HX, with decades of experience extending the life of equipment and recapturing thermal efficiencies, was the ideal partner for this project.

Following an analysis by the CT/HX team, Lyons outlined an approach for the refurbishment of the cooling towers, which included cleaning the units, recoating the basins, and replacing the intake louvers and media filters.

Challenges

The inefficiency of Bowling Green Metalforming’s existing cooling towers was a primary concern that drove the decision for refurbishment in order to defer large capital expenditures. Furthermore, time was of the essence, and acquiring new equipment would have taken too long.

Lyons’ partnership with CT/HX provided a unified team that was able to exceed customer expectations. Service technicians worked closely with the building maintenance staff to coordinate all the necessary work to prevent interruptions and maintain strict safety protocols.

After properly disposing of all existing PVC heat transfer media and drift eliminators, the team cleaned the cold-water basins of accumulated dirt, scale, and debris, and high-pressure power washed the interior of each tower. The interiors of the cooling towers were grinded down using a mechanically powered wire brush and abrasive disc grinder to prepare the sheet metal for new protective caulking and coatings. The team then reinstalled refreshed spray header branches that had been removed before installing new PVC CF80Max high efficiency eliminators in each of the towers.

Cooling Towers refurbished and set by Lyons Mechanical Services and CT/HX
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Equipment

The towers were patched with G-235 galvanized plate material, and the team furnished and installed new PVC Therma Cross Fill Media kits — a type of fill media that is designed to improve thermal performance in cooling towers.

The team also installed a custom PVC framed CL80 air inlet louver panel, and new PVC CF80Max high efficiency eliminators, designed to capture large water droplets caught in the cooling tower air stream.

Results 

After refurbishing the four cooling towers, efficiency and performance drastically increased. Within the first 15 minutes of putting one of the refurbished towers online, the hot well temperature decreased by 10 degrees. Lowering the hot well temperature indicates better heat transfer, which can translate to operational cost savings. The refurbished towers not only enhance the longevity and efficiency of the existing equipment, but also represent significant cost savings for Bowling Green Metalforming.

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Donnie Franklin
Donnie Franklin
Director of Operations, Service and Controls, Lyons Mechanical Services

Donnie Franklin serves as Director of Operations, Service and Controls at Lyons Mechanical Services (Lyons), where he oversees the day-to-day operations of the company’s service and building automation divisions. With more than two decades of industry experience, Donnie directs operational strategy, budget management, performance standards, and workflow efficiency across service, production, quality control, logistics, and controls integration. His leadership is centered on driving operational excellence, expanding Lyons’ technological capabilities, and delivering reliable, high-performance solutions to customers.

Donnie began his career with Lyons more than 20 years ago, joining the company as a Technician performing service work and controls installations. As he gained experience in the design, programming, and functionality of complete HVAC systems, he advanced into controls-focused roles—including Controls Technician, Controls Programmer/Integrator, and eventually Senior Project Manager.

Donnie began his career with Lyons more than 20 years ago, joining the company as a Technician performing service work and controls installations. As he gained experience in the design, programming, and functionality of complete HVAC systems, he advanced into controls-focused roles—including Controls Technician, Controls Programmer/Integrator, and eventually Senior Project Manager.

Donnie’s depth of field expertise, combined with his commitment to continuous improvement and innovation, has established him as a key leader in advancing Lyons’ integrated HVAC and building automation services. His dedication to operational excellence and customer-focused service continues to strengthen Lyons’ position as a regional leader in high-performance mechanical systems and building automation technologies.

  • Certified Energy Manager (CEM®)
  • HVAC Master license
James Watkins
James Watkins
Chief Estimator
James attended Eastern Kentucky University, majoring in Construction Technology from 1988 to 1992. After college James began his career working for general contractor in various roles which included project management, safety, and estimating. James has over 25 years of experience in the construction industry. James has received several certificates of training in various estimating software programs, which allow him to perfect his expertise as chief estimator for Lyons Company.
George Whitney
George Whitney
Operations Manager, Lyons Company
George began with Lyons Company in 2003, building up his trade skills before receiving his plumbing license in 2007. After successfully running small projects over the next five years, George received his HVAC Mechanics license in 2012 and was promoted to Project Superintendent. In 2013 George was promoted to Project Manager after completing two food-grade piping expansion projects at the JM Smucker facility. Since that time, George has continued as Project Manager leading projects at JM Smucker, US Tsubaki, Medical Center of Bowling Green, Kobelco, Sumitomo, and Western Kentucky University.
  • Master Plumber License
  • Journeyman HVAC License
Tom Haines
Tom Haines
Manager, Heavy Industrial & Distilleries
  • Journeyman Plumber License
  • Journeyman HVAC License
  • Master HVAC License

Stuart Cook

PE, LEED AP® BD+C

Engineering Manager

Stuart graduated from Western Kentucky University in 2008 with a Bachelors of Science Degree in Mechanical Engineering, and began employment with Lyons Company immediately after. Stuart holds a Professional Engineering license in both Kentucky and Tennessee, and is a Licensed Mechanical Contractor in Tennessee.

  • Professional Engineering license
  • LEED Accredited Professional
  • Licensed Mechanical Contractor
Jorelle Minor
Jorelle Minor
Safety & Training Manager
Jorelle is a Marine Corp Veteran with numerous academic achievements in various fields of study. Since joining Lyons Company in 2003 Jorelle has held many key positions within the organization. Most recently completing the OSHA 30 hour course and taking over the role as the Safety Manager.
Chad Childress
Chad Childress
President, Lyons Mechanical Services

Chad Childress serves as President of Lyons Mechanical Services (Lyons), where he oversees the company's strategic direction and performance. With nearly three decades of industry experience, Chad leads with a focus on growth and innovation, championing business development, customer retention, and the rapid expansion of service and maintenance plans. His leadership is grounded in a deep understanding of operations and a long-standing commitment to delivering exceptional Proactive, World-Class Service.

Chad began his career at Lyons in 1996 as an HVAC service technician and steadily advanced through the ranks due to his dedication, technical expertise, and strong relationships with both customers and Team Members. Prior to his promotion to President, Chad served as Operations Manager, where he shaped the procedures and standards that ensured consistency in the areas of safety, productivity, quality, Team Member development, and customer satisfaction.

A graduate of the Bowling Green Regional Technology Center’s Air Conditioning Technology Program, Chad holds HVAC Journeyman and Masters Licenses, a Plumbing Journeyman and Master License, and Tridium Niagara AX Certification. Chad continues to be a driving force behind Lyons’ success. His unwavering commitment to his craft and his clients has propelled Lyons to become a regional leader in the engineering, design, installation, and maintenance of cutting-edge building automation systems.

  • Master Plumber License
  • HVAC Master license
  • Tridium Niagara AX Certified