Effective Monitoring of Cooling Towers


Cooling towers are required to remove heat from the water that has been used to cool many different systems throughout the mill. The water travels in an endless loop, from all the systems and then back to the tower where the heat is removed and back to the same systems. Basically, after the cooling water has been used to remove any excess heat from any system, it is pumped to the roof of the mill where the cooling tower is situated. The water is pumped into the top of the tower; an area called a distribution basin (hot water side). The basin has metering orifices that allow even distribution of the water over the fill. The fill acts like a radiator in a car. On top of the cooling tower, there is a large fan that draws the air through the fill, cooling the water and exhausting the hot air to atmosphere. After the water has traveled through the fill, it reaches the cold water basin at the bottom of the tower where it drains by gravity back into a holding tank in the mill. From there it is pumped to all the different systems before heading back to the tower once again. The efficiency of the tower is measured by the temperature different

  • If your online vibration monitoring systems are limited to only overall alarming, it would be beneficial to look at a method to plug into it with your vibration analyzers. Without the ability to collect spectra and waveforms, there is a good chance of missing certain faults in the drive train. This could lead to unscheduled downtime and possibly a catastrophic failure. There had been instances when fan blades have disintegrated due to blade fatigue, causing serious damage to the tower and endangering lives. There are excellent monitoring systems on the market today, but unfortunately industry has been slow adapting.
  • Another PDM tool that should be used on monitoring cooling tower gearboxes is oil analysis. Trending the different elements in the oil has proven to be an affective way of giving early warning detection of bearing and gear failures in any oil lubricated drive systems. Oil analysis integrates well with vibration analysis.
  • It should be noted that walk around data collection can be very effective but you have to be aware of its limitations, in certain areas it just cannot replace a good online system.


Water quality monitoring in cooling towers

Cooling tower is structure which you can easily find in many industries, power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semi-conductor plants, hospital etc. Cooling towers are used to cool the water used in industrial process. It is a special type of device which uses the air to lower the water temperature. In cooling tower, water and air comes in contact with each other and this process decreases the water temperature. During this process some volume of water evaporates. This remaining low temperature water is being recalculated in the process and used again for treatment.

In easy words, the purpose of a cooling tower is to cool down water that gets heated up by industrial equipment and processes. The water that comes in the cooling tower is hot from the industrial process and goes out of the cooling tower cold. In the recalculated water process, warm water from a system is piped into a cooling tower and dispersed over a larger surface area. This increases evaporation and removes heat. Fans are used to draw air across the fill and assist in evaporation, cooling the water. The cooled water flows back down the system and to the heat source. As water evaporates, more water is needed to keep the system functioning. As water is introduced to the system, so are traces of other elements. These elements and those from air contribute to the build-up of microorganisms.