Upgrading Reliability: Tropicana’s New Stainless-Steel Filter House

When a plant’s turbine generator depends on a filter house that has weathered three decades of service, the time eventually comes when maintenance is no longer enough — replacement becomes essential. Our team was brought in to deliver a modern, long-lasting solution that would not only enhance operational reliability but also improve worker safety for years to come.

This Tropicana project centered on removing the original 30-year-old filter house perched atop the turbine generator and replacing it with a newly fabricated, 304 stainless-steel unit. The new structure — measuring 30’ x 30’ x 12’ tall, and weighing 30,000 pounds — was engineered to withstand the harshest conditions and drastically extend the system’s lifespan.

Before fabrication could begin, our team spent two weeks performing detailed measurements and 3D laser scanning to ensure the drawings and final product would be a perfect fit. Aluminum access platforms were added to provide the client with a significantly safer and more stable way to reach the filters during routine maintenance The fabrication phase spanned five months, resulting in a precisely built stainless-steel assembly ready for installation.

Upon arrival at the plant, it took two weeks to assemble the structure onsite and fully seal-weld every seam. The final swap — removing the old filter house and installing the new one — was completed during a critical four-day turbine outage. Every hour counted, and the team delivered flawlessly within the shutdown window.

Midway through the project, the plant made the decision to replace an expansion joint located directly beneath the filter house — a component tightly surrounded by the existing structure. To accommodate this change, our crew safely disconnected and slid beams out of the way, creating the clearance needed to perform the additional work without compromising structural integrity or project timing.

With the new stainless-steel filter house in place, the plant can expect decades of reliable service with no need for future replacements. Just as importantly, the addition of the internal platforms means the maintenance team no longer has to remove and replace seventy-five 30-pound filters using ladders. The result is a safer work environment, reduced risk, and a more efficient maintenance process.

This project stands as a testament to careful planning, precise execution, and the ability to adapt to evolving needs — all while delivering a solution built to last.