Method for utilizing multiple simultaneous independent water sources in a cooling tower.

Abstract

A cooling tower system is disclosed. [Solution] The cooling system includes a cooling tower, at least two make-up water inlet streams configured to supply water to the cooling tower, a blowdown stream configured to remove water from the cooling tower, at least one sensor that monitors water in each of the make-up water inlet streams, and a controller operably connected to the at least one sensor.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to control and monitoring of makeup water for cooling towers. More specifically, this disclosure relates to a method for simultaneously utilizing independent makeup water sources. [Background technology]

[0002] Water cooling towers are used in large-capacity heat exchange systems such as those found in refineries and chemical manufacturing plants. They are used to remove absorbed heat from a circulating water coolant by evaporating a portion of the coolant within the tower. The remaining coolant can be extracted by a pump from a reservoir or sump at the base of the tower and continuously supplied through the heat load. Because large amounts of water are evaporated in such systems, scale, silt, or other water contaminants can accumulate in the recirculating water over time. Summary of the Invention [Problem to be solved by the invention]

[0003] Various chemicals can be added to the recirculating cooling water to help prevent or limit the extent to which fouling occurs on surfaces that the water contacts. In a typical operating environment, technicians may take cooling water samples from the cooling water system and perform chemical analyses of the samples. Based on the analyses, the technicians may adjust the types of chemicals added to the cooling water. In many cases, technicians may only be on-site at a facility to perform cooling water analyses on a limited basis, such as once a week or once a month. As a result, changes in a facility's process conditions may not be detected until some time after the process conditions are altered. Furthermore, even if the cooling water chemistry is changed to accommodate changed process conditions, such changes are generally reactive rather than predictive to prevent undesirable cooling water conditions. [Means for solving the problem]

[0004] A cooling tower system is disclosed that includes a cooling tower, at least two make-up water inlet streams configured to supply water to the cooling tower, a blowdown stream configured to remove water from the cooling tower, at least one sensor that monitors water in each of the make-up water inlet streams, and a controller operably connected to the at least one sensor.

[0005] In some embodiments, the at least two makeup water inlet streams comprise three makeup water inlet streams.

[0006] In some embodiments, the at least two makeup water inlet streams are connected to a pipe connected to the cooling tower, the pipe conveying water from the at least two makeup water inlet streams into the cooling tower.

[0007] In some embodiments, at least one sensor is a conductivity sensor.

[0008] In some embodiments, the at least one sensor is a flow sensor.

[0009] In some embodiments, each makeup water inlet stream is monitored by at least two sensors.

[0010] In some embodiments, the at least two sensors are a conductivity sensor and a flow sensor.

[0011] In some aspects, the controller stores the conductivity setpoint.

[0012] In some aspects, the cooling water system further includes a distributed control system operably connected to the controller.

[0013] In some aspects, the system does not include a makeup water holding tank configured to supply water to the cooling tower.

[0014] A method for controlling cooling water treatment is also provided that includes receiving data from at least one sensor monitoring water in at least two makeup water inlet streams configured to supply water to a cooling tower, and creating a virtual makeup stream from the data received from the at least one sensor.

[0015] In some embodiments, data is received from at least three sensors monitoring water in three makeup water inlet streams.

[0016] In some aspects, the method includes dosing a chemical additive into the cooling tower based on characteristics of the virtual make-up stream.

[0017] In some embodiments, the method includes adjusting the blowdown based on characteristics of the virtual make-up flow.

[0018] In some embodiments, the method includes monitoring the corrosion rate of copper and / or mild steel in the makeup water inlet stream.

[0019] In some embodiments, the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and any combination thereof.

[0020] In some embodiments, the method further comprises adjusting the ratio of the first stream of makeup water to the second stream of makeup water.

[0021] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the present disclosure will be described hereinafter, which form the subject of the claims of this application. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the present disclosure as set forth in the appended claims. [Brief explanation of the drawings]

[0022] A detailed description of the invention is set forth herein below with specific reference to the following drawings.

[0023] [Figure 1] The inhibitor set point versus the percentage of the replenishment source is shown.

[0024] [Figure 2] The corrosion rate of mild steel is shown.

[0025] [Figure 3] The corrosion rate of copper is shown.

[0026] [Figure 4] Calculation of the concentration cycle is shown.

[0027] [Figure 5] 1 illustrates an embodiment of a cooling tower system. DETAILED DESCRIPTION OF THE INVENTION

[0028] Various embodiments are described below with reference to the drawings, in which like elements are generally referred to by like numerals. The relationship and function of the various elements of the embodiments may be better understood by reference to the detailed description that follows. However, the embodiments are not limited to those illustrated in the drawings. It should be understood that the drawings are not necessarily to scale, and in some cases, details not necessary to an understanding of the embodiments disclosed herein, such as conventional manufacturing and assembly, may be omitted.

[0029] Typically, in a multiple make-up source scenario, the only viable alternative for the customer is to install a large equalization tank and direct all make-up flows to that tank. In that scenario, only one water flow originating from the tank is used as make-up for the cooling tower. This application requires a large capital expenditure and a large footprint for the tank. Also, the tank does not allow the plant to account for how each of the contributing flows may affect the composite make-up flow.

[0030] The present disclosure allows for individual stream monitoring without the need for an equalization tank, and it also allows for real-time changes to corrosion / scale control chemistry set points as the ratios of multiple streams entering the cooling tower change.

[0031] A cooling tower system is disclosed that includes a cooling tower, at least two make-up water inlet streams configured to supply water to the cooling tower, a blowdown stream configured to remove water from the cooling tower, at least one sensor that monitors water in each of the make-up water inlet streams, and a controller operably connected to the at least one sensor.

[0032] Each makeup water inlet stream may have one, two, three, four, five, or six sensors monitoring the makeup water. The sensors may be configured to detect various properties of the makeup water. Examples of properties measured by the sensors include, but are not limited to, ORP, dissolved oxygen (DO), conductivity, pH, turbidity, concentrations of specific chemicals (such as biocides, scale inhibitors, friction reducers, acids, bases, and / or oxygen scavengers), ion (phosphate) levels (e.g., determined empirically, automatically, fluorometrically, electrochemically, colorimetrically, directly measured, or calculated), temperature, pressure, flow rate, or total dissolved or suspended solids.

[0033] In some embodiments, at least one sensor is a flow sensor. In some embodiments, there are two sensors monitoring each supply line: a flow sensor and a conductivity sensor.

[0034] As another example, the sensor may be an optical sensor to provide measurements indicative of the concentration and / or size of particles in the cooling water. For example, an optical sensor may be used to measure the turbidity and / or light scattering properties of the cooling water. An increase in the concentration of particles in the cooling water may be associated with scale fouling components and indicate a scale fouling mechanism. Additionally or alternatively, an optical sensor may be used to measure fouling formation on the cooling water flow-side surface of a heat exchanger or an analog of a heat exchanger, such as a metal coupon or test strip exposed to the same cooling water conditions to which the heat exchanger is exposed. The optical sensor may optically evaluate the fouling material formed on the monitored surface to determine the characteristics of the fouling material and, accordingly, whether the fouling material is associated with a scale fouling mechanism (or corrosion or biofouling).

[0035] Corrosion rates can be monitored in makeup water lines and cooling towers. Cooling tower systems can include copper and mild steel corrosion monitoring technology for each stream and use that information to help avoid potential downstream corrosion problems in the cooling tower in real time. This is especially important in applications involving high-efficiency chillers, as they typically have thinner tube walls in their heat exchangers and require more careful monitoring of corrosion levels.

[0036] As another example, in situations where a chemical additive is introduced into the cooling water stream to combat a potential source of fouling, the additive may include a fluorescently tagged polymer or an inert fluorescent tracer that can be fluorimetrically analyzed to determine the concentration of the chemical in the cooling water. The controller may evaluate the consumption rate of the chemical additive based on the fluorescent response to help determine whether the detected cooling water fouling is associated with the fouling mechanism in process or a potentially different fouling mechanism.

[0037] As used herein, the term "scaling" refers to the fouling of heat exchange surfaces by particulate matter from or formed in cooling water, including, but not limited to, components such as calcium carbonate, calcium phosphate, magnesium silicate, silica, manganese oxide, aluminum phosphate, silt, and sand.

[0038] The term "corrosion fouling" refers to the fouling of heat exchange surfaces by corrosion-formed deposits, primarily metal oxides, which can be formed in situ or by breakage and redeposition from elsewhere in the system.

[0039] For example, evaporation of cooling water can lead to concentrations of salts (e.g., calcium, sodium, magnesium) in the cooling water stream recycled through the system. These salts can form scaling deposits on heat exchanger surfaces in contact with the cooling water. As another example, if the cooling water contains organic material and microorganisms, biofilms can build up on heat exchanger surfaces in contact with the cooling water. As yet another example, corrosion products can develop within the cooling water stream due to, for example, oxidation of metal components (e.g., iron, aluminum, and / or zinc). These corrosion products can also build up on heat exchanger surfaces in contact with the cooling water. Regardless of the mechanism or cause of fouling, the buildup of a barrier layer on heat exchanger surfaces in contact with the cooling water can reduce the efficiency of heat transfer through the heat exchanger.

[0040] To help reduce or eliminate potential fouling conditions in the cooling water flowing through the heat transfer network, one or more chemicals can be added to the cooling water to inhibit the formation and / or deposition of fouling substances. Examples of chemical additives that can be injected into the cooling water include, but are not limited to, polymers (dispersants and scale inhibitors), organophosphorus compounds such as phosphinosuccinic acid oligomers (PSO, scale and corrosion inhibitors), zinc (corrosion inhibitors), orthophosphates (corrosion inhibitors), polyphosphates (scale and corrosion inhibitors), biocides, dispersants, and combinations thereof. Additionally or alternatively, one or more chemical additives can be injected into the cooling water to adjust the pH of the cooling water. Examples of pH adjustment control agents include mineral acids, organic acids, and inorganic bases.

[0041] The disclosed methods and systems can be scaled to accommodate more than two makeup water streams from independent sources. In some embodiments, the system includes three makeup water inlet streams, four makeup water inlet streams, five makeup water inlet streams, or six makeup water inlet streams. Each inlet stream can be connected to a single cooling tower inlet pipe without passing through a makeup water holding tank. Alternatively, each inlet stream can be fed into the cooling tower independently.

[0042] The cooling system and associated treatment program are optimized and adjusted in response to individual changes in the inlet make-up water flow ratio using predetermined look-up tables stored in the controller.

[0043] Each measured parameter may have a predetermined set point or operating range that the system should be maintained in. In some embodiments, the controller stores conductivity, pH, or corrosion set points.

[0044] This process of measuring makeup water properties and adjusting flow rate or additive dosage can be accomplished in real time using either cloud-based PLC calculations or on-site PLC calculations using Nalco Cooling Water Optimizer to provide updated real-time or near real-time adjustments to the local PLC.

[0045] The dosage of treatment chemicals may depend on the ratio of the incoming makeup water flow to the resulting water profile.

[0046] 5, one embodiment of a cooling tower system 100 is shown. System 100 includes a cooling tower 101, at least two makeup water inlet streams 102 configured to supply water to cooling tower 101, a blowdown stream 103 configured to remove water from cooling tower 101, at least one sensor 104 that monitors water in each of the makeup water inlet streams 102, and a controller 105 operably connected to the at least one sensor 104.

[0047] The at least two makeup water inlet streams 102 are connected to pipes 107 that are connected to the cooling tower 101, and the pipes 107 carry water from the at least two makeup water inlet streams 102 into the cooling tower 101. The makeup streams do not have to be connected to pipes that carry water to the cooling tower, but can be connected directly to the cooling tower to provide makeup water.

[0048] The cooling tower system may include a distributed control system 108 operably connected to the controller. The PLC controller 105 receives input from the makeup water flow sensor 104. The PLC controller is pre-programmed using performance data from the Optimizer 109 of any combination of makeup water flows to generate a virtual combined flow. The PLC controller 105 identifies appropriate control parameters according to the makeup ratio of the virtual combined flow. The control parameters are exported to the controller 110 and the distributed control system 108 to operate the chemical pumps and blowdown valves. The control parameters do not need to be exported everywhere, only to the locations that control the blowdown valves and chemical pumps.

[0049] In a cooling tower, water is lost through evaporation 111 and make-up water must be added. The fluid travels through line 117, passing through filter 112 on its way to heat exchanger 113. The fluid is then returned to the cooling tower 101. The fluid in line 117 can be treated with chemicals by injecting the agents through line 114. Make-up water line 102 can also be treated with chemical additives by injecting them through line 114 directly into the make-up water line 102 or into the cooling tower 101. The chemicals can be stored in tank 115 and pumped into the target line.

[0050] A sample of the fluid in line 117 can be drawn using line 116 and analyzed using the water analysis unit 110. The characteristics of the fluid in line 117 can be transmitted to the controller 110, where they can be compared to stored set points. The controller 110 then determines whether to adjust the flow rate of the makeup water or the dosage of chemical additives. The makeup water sensor reports to the PLC controller 105, which exports corresponding control parameters to the control device 110 based on the makeup ratio of the composite stream.

[0051] In certain embodiments, the control system includes a monitoring and control unit that includes a controller and a plurality of sensors. Each of the plurality of sensors can be in communication with the controller. For example, if the unit includes five sensors, each of the five sensors can be in communication with the controller. In certain embodiments, the controller can be mounted on a skid or other type of support member to allow movement.

[0052] A method for controlling cooling water treatment is also provided that includes receiving data from at least one sensor monitoring water in at least two makeup water inlet streams configured to supply water to a cooling tower, and creating a virtual makeup stream from the data received from the at least one sensor.

[0053] A virtual make-up stream refers to a stream that is made up of a specific percentage of the make-up water inlet stream. Based on the characteristics of each make-up water stream, such as flow rate and conductivity, the characteristics of the combined stream can be predicted when two or more make-up streams are mixed.

[0054] Data received from sensors on the makeup water inlet stream is analyzed to generate a virtual stream, and chemical additive dosages and blowdown flow rates can be adjusted based on the characteristics of the virtual stream.

[0055] In some embodiments, the method may include adjusting the blowdown and cycles of concentration (CoC) of the cooling system based on changes in the quality of the makeup water stream.

[0056] As used herein, the term "controller" refers to a manual operator or electronic device having components such as a processor, memory devices, digital storage media, a communications interface including communications circuitry operable to support communications across any number of communications protocols and / or networks, a user interface (e.g., a graphical user interface that may include a cathode ray tube, liquid crystal display, plasma display, touch screen, or other monitor), and / or other components.

[0057] The controller is preferably operable to integrate with one or more application specific integrated circuits, programs, computer executable instructions or algorithms, one or more hardwired devices, wireless devices, and / or one or more mechanical devices. Additionally, the controller is operable to integrate the feedback, feedforward, and / or predictive loops of the present invention. Some or all of the controller system functionality may reside in a central location, such as a network server, for communication over a local area network, a wide area network, a wireless network, an internet connection, a microwave link, an infrared link, a wired network (e.g., Ethernet), etc. Additionally, other components, such as signal conditioners or system monitors, may be included to facilitate signal transmission and signal processing algorithms.

[0058] In certain embodiments, the controller includes hierarchical logic for prioritizing any measured or predicted properties related to system parameters. For example, the controller may be programmed to prioritize system pH over conductivity, or vice versa. It should be understood that the purpose of such hierarchical logic is to enable improved control over system parameters and to avoid circular control loops.

[0059] In some embodiments, the monitoring and control unit and associated methods include an automatic controller. In some embodiments, the controller is manual or semi-manual. For example, if the system includes one or more data sets received from various sensors within the system, the controller can automatically determine which data points / data sets to further process, or an operator can make such decisions, partially or completely. For example, a data set for an industrial body of water may include variables or system parameters such as ORP, dissolved oxygen (DO), conductivity, pH, turbidity, concentrations of specific chemicals (such as biocides, scale inhibitors, acids, bases, etc.), ion levels (e.g., determined empirically, automatically, fluorometrically, electrochemically, colorimetrically, directly measured, or calculated), temperature, pressure, flow rate, total dissolved or suspended solids, etc. Such system parameters are typically measured with any type of suitable data acquisition equipment, such as sensors specifically designed for these parameters, e.g., pH sensors, ion analyzers, temperature sensors, thermocouples, pressure sensors, corrosion probes, and / or any other suitable device or sensor. The data collection device is preferably in communication with the controller and, in some embodiments, may have advanced functionality provided by the controller (including any part of the control algorithms described herein).

[0060] The monitoring and control unit may include multiple sensors capable of analyzing the water and transmitting data regarding the water to the controller. The multiple sensors may include, for example, sensors for measuring conductivity, pH, ORP, biocide concentration, turbidity, temperature, flow rate, and DO in the water. The monitoring and control unit may include any of these sensors, all of these sensors, a combination of two or more of these sensors, or one or more additional sensors not specifically mentioned herein, and the sensors may be in communication with the controller. Other types of sensors contemplated by the present disclosure include, but are not limited to, oil-in-water sensors, total dissolved solids sensors, and total suspended solids sensors.

[0061] The monitoring and control system of the present disclosure, in certain embodiments, includes one or more chemical injection pumps. Each chemical injection pump may be in fluid communication with a storage device. Each storage device may contain one or more chemicals, and the chemical injection pump may transport these chemicals to a body of water. In some embodiments, the chemical injection pump includes the storage device. The chemical injection pumps may be in communication with a controller in any manner, such as by any combination of wired, wireless, electronic, cellular, infrared, satellite, or any other type of communication network, topology, protocol, standard, etc. Thus, the controller can send signals to the pumps to control their chemical delivery rates.

[0062] In certain embodiments, a monitoring and control system is implemented in which multiple sensors provide continuous or intermittent feedback, feedforward, and / or predictive information to a controller, which can relay this information to a relay device, such as a Nalco Global Gateway, which can transmit this information via cellular communication to a remote device, such as a cell phone, computer, and / or any other device capable of receiving cellular communication. The remote device can interpret the information and automatically send a signal (e.g., an electronic instruction) back to the controller through the relay device, causing the controller to make certain adjustments to the output of the pump. This information can also be processed internally by the controller, which can automatically send a signal to the pump to, for example, adjust the amount of chemical injection. Based on information received by the controller from multiple sensors or from remote devices, the controller can send signals to various pumps to automatically adjust the amount of chemical the pumps are injecting into the water in real time.

[0063] Alternatively, an operator of a remote device receiving cellular communications from the controller can manually operate the pumps through the remote device. The operator can communicate instructions to the controller through the remote device, cellularly, or otherwise, and the controller can adjust the chemical addition rate of the chemical injection pumps. For example, the operator can receive a signal or alert from the remote device via cellular communications from the controller and use the remote device to send instructions or signals back to the controller to turn on one or more of the chemical injection pumps, turn off one or more of the chemical injection pumps, increase or decrease the amount of chemical added to the water by one or more of the injection pumps, or any combination of the foregoing. The controller and / or remote device can also automatically make any of the aforementioned adjustments or corrections without the operator actually sending or entering instructions. Preset parameters or programs are entered into the controller or remote device to enable the controller or remote device to determine whether a measured characteristic is outside of an acceptable range. Based on information received by the multiple sensors, the controller or remote device can adjust the pumps appropriately or send an appropriate alert.

[0064] In certain embodiments, the remote device or controller may include appropriate software for receiving data from multiple sensors and determining whether the data indicates that one or more measured characteristics are within or outside of an acceptable range. This software may also enable the controller or remote device to determine appropriate action to take to correct a characteristic that is outside of an acceptable range. For example, if the measured pH is above an acceptable range, the software may enable the controller or remote device to make this determination and take corrective action, such as alerting a pump to increase the flow of acid into the body of water.

[0065] The monitoring and control systems and / or controllers disclosed herein may incorporate programming logic to convert analyzer signals from multiple sensors into pump regulation logic and, in certain embodiments, individually control one or more of multiple chemical injection pumps. Non-limiting, illustrative examples of the types of chemical injection pumps that may be operated include chemical injection pumps responsible for the injection of biocides, scale inhibitors, friction reducers, acids, bases, sulfites, oxygen scavengers, and any other type of chemical that may prove useful in a particular aqueous industrial system. Specific examples of biocides, scale inhibitors, friction reducers, acids, bases, sulfites, and oxygen scavengers are all well known in the art, and all examples of such chemicals are within the scope of the present disclosure.

[0066] The sensors disclosed herein are operable to sense and / or predict a property associated with a water or system parameter and convert the property into an input signal, e.g., an electrical signal, that can be transmitted to a controller. A transmitter associated with each sensor transmits the input signal to the controller. The controller is operable to receive the transmitted input signal, convert the received input signal into a numerical input value, analyze the numerical input value to determine whether the numerical input value is within an optimal range, generate an output value, convert the numerical output value into an output signal, e.g., an electrical signal, and transmit the output signal to a receiver, e.g., a pump incorporating such receiver functionality or a remote device, such as a computer or cell phone incorporating receiver functionality. The receiver may be operable to receive the output signal and alert an operator to adjust the pump flow rate, or automatically change the pump flow rate if the output value is not within an acceptable range for that property.

[0067] The method is optionally repeated for multiple different system parameters, each with unique associated characteristics, or alternatively, all system parameters may be analyzed simultaneously by multiple sensors.

[0068] Data transmission of measured parameters or signals to chemical pumps, alarms, remote monitoring devices such as computers or cell phones, or other system components may be accomplished using any suitable device and across any number of wired and / or wireless networks, including, by way of example, WiFi, WiMAX, Ethernet, cable, digital subscriber line, Bluetooth, cellular technologies (e.g., 2G, 3G, Universal Mobile Telecommunications System (UMTS), GSM, Long Term Evolution (LTE), etc.). The Nalco Global Gateway is an example of a suitable device. Any suitable interface standard, such as an Ethernet interface, a wireless interface (e.g., IEEE 802.11a / b / g / x, 802.16, Bluetooth, optical, infrared, RF terminals, etc.), Universal Serial Bus, telephone networks, etc., and combinations of such interfaces / connections may be used.

[0069] As used herein, the term "network" encompasses all of these data transmission methods. Any of the described devices (e.g., archiving systems, data analysis stations, data acquisition devices, processing devices, remote monitoring devices, chemical injection pumps, etc.) may be connected to each other using the above-described or other suitable interfaces or connections.

[0070] In some embodiments, system parameter information is received from the system and archived. In certain embodiments, system parameter information is processed according to a timetable or schedule. In some embodiments, system parameter information is processed immediately, in real time or substantially real time. Such real-time reception may include, for example, "streaming data" over a computer network.

[0071] The method of the present disclosure can be used in a variety of applications. For example, the oxidizing composition can be used as a sacrificial oxidant to reduce the demand for converted chlorine dioxide molecules in non-biocidal applications where chlorite is a limitation. This approach can enable the use of chlorine dioxide in freshwater or influent treatment, in wastewater treatment where certain contaminants may require oxidation, in water streams with chemically reducing environments, in water streams with significant anaerobic environments to create aerobic environments, in aquatic systems where higher dosages of oxidizing biocides may have detrimental effects but lower dosages can be beneficial, and in open recirculating cooling water systems in the food and beverage industry, paper manufacturing, and mining industries. [Example]

[0072] Example 1

[0073] The scenario tested for this invention consisted of three makeup water streams with two sensors (flow rate and conductivity) for each makeup water stream. The makeup water sensors were connected to a PLC controller which received flow rate and conductivity inputs for each individual makeup stream. A virtual composite flow was generated and the control parameters for this particular virtual composite flow were output to a distributed control screen and a cooling tower controller. The distributed control screen controlled the blowdown valve and the cooling tower controller controlled the chemical pump and conductivity set point.

[0074] Figure 1 shows the flow rate and mixing conditions as they change from the first flow to the second flow. For this stage of the experiment, the inventors also verified the change in the mixing ratio and the change in the chemical set point. It clearly shows that when the virtual combined flow varies based on the load and cooling tower level, the programming outputs the corresponding control parameters to protect the system.

[0075] As shown in Figures 2 and 3, the instantaneous mild steel corrosion rate (Figure 2) and copper corrosion rate (Figure 3) remain within specifications. Although the corrosivity of the make-up stream affects the instantaneous corrosion rate of the system water, the control can be modified based on the make-up ratio so the system remains protected.

[0076] The concentration cycle and tower system conductivity are shown in Figure 4. This shows the varying concentration cycle due to the hypothetical combined flow of makeup water constantly changing the conductivity, resulting in higher or lower CoC. The decrease in tower conductivity is to protect the system, based on the makeup water ratio. As more corrosive water is introduced into the system, the conductivity is decreased to protect the system.

[0077] All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. The present invention may be embodied in many different forms, and certain preferred embodiments of the present invention are described in detail herein. The present disclosure is an exemplification of the principles of the present invention and is not intended to limit the invention to the specific embodiments illustrated. Additionally, unless expressly stated otherwise, the term "a" is intended to include "at least one" or "one or more." For example, "a sensor" is intended to include "at least one sensor" or "one or more sensors."

[0078] Any ranges given in either absolute or approximate terms are intended to be inclusive, and any definitions used herein are intended to be illustrative, not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, all ranges disclosed herein should be understood to encompass all subranges subsumed therein, including all fractional and whole values.

[0079] Any composition disclosed herein can comprise, consist of, or consist essentially of any element, component, and / or ingredient disclosed herein, or any combination of two or more of the elements, components, or ingredients disclosed herein.

[0080] Any method disclosed herein may comprise, consist of, or consist essentially of any method step(s) disclosed herein, or any combination of two or more method steps disclosed herein.

[0081] The transitional phrase "comprising," which is synonymous with "including," "containing," or "characterized by," is inclusive or open-ended and does not exclude additional, unrecited elements, components, ingredients, and / or method steps.

[0082] The transitional phrase "consisting of" excludes any element, component, ingredient, and / or method step not specified in the claim.

[0083] The transitional phrase "consisting essentially of" limits the scope of a claim to certain elements, components, ingredients, and / or steps, and those that do not materially affect the basic and novel characteristics of the claimed invention.

[0084] Unless otherwise specified, all molecular weights referred to herein are weight average molecular weights and all viscosities were measured at 25°C using neat (undiluted) polymer.

[0085] As used herein, the term "about" refers to a cited value that is within error resulting from the standard deviation found in their respective testing measurements; where such error cannot be determined, "about" may refer, for example, to within 5% of the cited value.

[0086] Furthermore, the present invention encompasses all possible combinations of some or all of the various embodiments described herein. It should also be understood that various changes and modifications to the preferred embodiments of the present invention described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. Accordingly, it is intended that such changes and modifications be covered by the appended claims.

[0087] Description

[0088] Description 1: A cooling tower system comprising: a cooling tower; at least two make-up water inlet streams configured to supply water to the cooling tower; a blowdown stream configured to remove water from the cooling tower; at least one sensor monitoring water in each of the make-up water inlet streams; and a controller operably connected to the at least one sensor.

[0089] Statement 2: The system of statement 1, wherein the at least two makeup water inlet streams include three makeup water inlet streams.

[0090] Statement 3: The system of statements 1 or 2, wherein the at least two makeup water inlet streams are connected to a pipe connected to the cooling tower, and the pipe conveys water from the at least two makeup water inlet streams into the cooling tower.

[0091] Statement 4: The system of any one of statements 1 to 3, wherein at least one sensor is a conductivity sensor.

[0092] Statement 5: A system described in any one of statements 1 to 3, wherein at least one sensor is a flow sensor.

[0093] Statement 6: The system of any one of statements 1-5, wherein each makeup water inlet stream is monitored by at least two sensors.

[0094] Statement 7: The system of statement 6, wherein the at least two sensors are a conductivity sensor and a flow sensor.

[0095] Statement 8: The system of any one of statements 1 to 7, wherein the controller stores the conductivity set point.

[0096] Statement 9: The system of any one of statements 1 to 8, further comprising a distributed control system operably connected to the controller.

[0097] Statement 10: The system of any one of statements 1-9, wherein the system does not include a makeup water holding tank configured to supply water to a cooling tower.

[0098] Statement 11: A method for controlling cooling water treatment, the method including: receiving data from at least one sensor monitoring water in at least two makeup water inlet streams configured to supply water to a cooling tower; and creating a virtual makeup stream from the data received from the at least one sensor.

[0099] Statement 12: The method of statement 11, wherein at least one sensor is a conductivity sensor.

[0100] Statement 13: The method of statement 11, wherein at least one sensor is a flow sensor.

[0101] Statement 14: The method of any one of statements 11-13, wherein data is received from at least three sensors monitoring water in three makeup water inlet streams.

[0102] Statement 15: The method of any one of statements 11-14, further comprising administering a chemical additive into the cooling tower based on characteristics of the virtual make-up stream.

[0103] Statement 16: The method of any one of statements 11-15, further comprising adjusting the blowdown based on characteristics of the virtual make-up flow.

[0104] Statement 17: The method of any one of statements 11-16, further comprising monitoring the corrosion rate of copper and / or mild steel in the makeup water inlet stream.

[0105] Statement 18: The method of any one of statements 11-17, wherein each makeup water inlet stream is monitored by at least two sensors.

[0106] Statement 19: The method of statement 15, wherein the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and combinations thereof.

[0107] Statement 20: The method of any one of statements 11-19, further comprising adjusting the ratio of the first stream of make-up water to the second stream of make-up water.

Claims

1. 1. A cooling tower system, comprising: Cooling towers and at least two make-up water inlet streams configured to supply water to the cooling tower; a blowdown flow configured to remove water from the cooling tower; at least one sensor monitoring the water in each of the makeup water inlet streams; a controller operably connected to the at least one sensor; The controller may include: receiving data from the at least one sensor; generating a virtual composite flow from the data received from the at least one sensor, the virtual composite flow being a mixture of the at least two makeup water inlet flows; and controlling the dosage of a chemical additive to the cooling water and the flow rate of a blowdown stream from the cooling tower based on the predicted flow rate and conductivity of the virtual combined stream.

1. A cooling tower system configured as follows:

2. The system of claim 1 , wherein the at least two makeup water inlet streams comprise three makeup water inlet streams.

3. 2. The system of claim 1, wherein the at least two makeup water inlet streams are connected to a pipe connected to the cooling tower, the pipe conveying water from the at least two makeup water inlet streams into the cooling tower.

4. The system of claim 1 , wherein the at least one sensor is a conductivity sensor.

5. The system of claim 1 , wherein the at least one sensor is a flow sensor.

6. The system of claim 1 , wherein each makeup water inlet stream is monitored by at least two sensors.

7. The system of claim 6 , wherein the at least two sensors are a conductivity sensor and a flow sensor.

8. The system of claim 1 , wherein the controller stores a conductivity set point.

9. The system of claim 1 further comprising a distributed control system operably connected to the controller.

10. 10. The system of claim 1, wherein the system does not include a makeup water holding tank configured to supply water to the cooling tower.

11. 1. A method for controlling cooling water treatment, the method comprising: receiving data from at least one sensor monitoring water in at least two makeup water inlet streams configured to supply water to a cooling tower; creating a virtual composite flow from the data received from the at least one sensor, the virtual composite flow being a mixture of the at least two makeup water inlet flows; and controlling a dosage of a chemical additive to the cooling water and a flow rate of a blowdown stream from the cooling tower based on the predicted flow rate and conductivity of the virtual combined stream.

12. The method of claim 11 , wherein the at least one sensor is a conductivity sensor.

13. The method of claim 11 , wherein the at least one sensor is a flow sensor.

14. The method of claim 11 , wherein data is received from at least three sensors monitoring water in three makeup water inlet streams.

15. 12. The method of claim 11, further comprising: dosing a chemical additive into the cooling tower based on the flow rate and conductivity of the virtual combined flow.

16. The method of claim 11 further comprising adjusting blowdown based on the flow rate and conductivity of the virtual combined flow.

17. 12. The method of claim 11, further comprising monitoring the corrosion rate of copper and / or mild steel in the makeup water inlet stream.

18. The method of claim 11 , wherein each makeup water inlet stream is monitored by at least two sensors.

19. 16. The method of claim 15, wherein the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and any combination thereof.

20. 12. The method of claim 11, further comprising adjusting the ratio of the first stream of make-up water to the second stream of make-up water.

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