Method of simultaneously utilizing multiple independent water sources in a cooling tower

Abstract

A cooling tower system is disclosed. The cooling system includes a cooling tower; at least two makeup 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 for monitoring water in each of the makeup water inlet streams; and a controller operably connected to at least one sensor.

Description

Background Technology

[0001] 1. Technology Field

[0002] The present disclosure generally relates to controlling and monitoring makeup water for cooling towers. More specifically, the present disclosure relates to a method of simultaneously utilizing independent sources of makeup water.

[0003] 2. Background Technology

[0004] Water cooling towers are used in large-capacity heat exchange systems, such as those found in oil refineries and chemical production plants. Cooling towers are used to remove heat absorbed from the circulating water coolant by evaporating a portion of the coolant within the tower. The remaining coolant can be extracted by pumps from a reservoir or sump at the base of the tower and continuously supplied through the heat load. Since a large amount of water evaporates in these systems, scale, silt, or other water contaminants can accumulate in the recirculating water over time.

[0005] Various chemicals may be added to the coolant to help prevent or limit the extent of fouling on surfaces in contact with the recirculating coolant. In a typical operating environment, a technician may take a sample of the coolant from the coolant system and perform a chemical analysis on the sample. Based on the analysis, the technician may adjust the type of chemicals added to the coolant. Often, technicians may perform coolant analysis only on-site, for example, once a week or once a month. As a result, changes in facility process conditions may not be detected until some point after the process conditions have changed. Furthermore, even if the coolant chemistry changes due to changes in process conditions, these changes are generally reactive rather than predictive, intended to prevent undesirable coolant conditions.

[0006] A cooling tower system is disclosed. The cooling system includes a cooling tower; at least two makeup 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 for monitoring water in each of the makeup water inlet streams; and a controller operably connected to at least one sensor.

[0007] In some embodiments, at least two supplementary water inlet streams include three supplementary water inlet streams.

[0008] In some embodiments, at least two makeup water inlet streams are connected to a pipe connected to a cooling tower, and the pipe carries water from at least two makeup water inlet streams into the cooling tower.

[0009] In some embodiments, at least one sensor is a conductivity sensor.

[0010] In some embodiments, at least one sensor is a flow sensor.

[0011] In some embodiments, each supplementary water inlet stream is monitored by at least two sensors.

[0012] In some embodiments, at least two sensors are a conductivity sensor and a flow sensor.

[0013] In some embodiments, the controller stores a conductivity setpoint.

[0014] In some embodiments, the cooling water system further includes a distributed control system operably connected to a controller.

[0015] In some embodiments, the system does not include a makeup water holding tank configured to supply water to the cooling tower.

[0016] A method for controlling cooling water treatment is also provided. The method includes the steps of: 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 generating a virtual makeup stream from the data received from at least one sensor.

[0017] In some embodiments, data is received from at least three sensors monitoring water in three supplementary water inlet streams.

[0018] In some embodiments, the method includes the step of introducing a chemical additive into a cooling tower based on the characteristics of a virtual replenishment stream.

[0019] In some embodiments, the method includes the step of controlling the blowdown based on the characteristics of the virtual supplement stream.

[0020] In some embodiments, the method includes the step of monitoring the corrosion rate of copper and / or mild steel in a makeup water inlet stream.

[0021] In some embodiments, the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and any combination thereof.

[0022] In some embodiments, the method includes the step of adjusting the ratio of supplementary water in the first stream to supplementary water in the second stream.

[0023] The foregoing has described the features and technical benefits of the present disclosure somewhat broadly and schematically to better facilitate the detailed description that follows. Additional features and benefits of the present disclosure that form the technical essence of the claims of this application will be described below. Those skilled in the art should understand that the disclosed concepts and specific embodiments can be readily utilized as a basis for modifying or designing other embodiments to achieve the same purpose of the present disclosure. Furthermore, those skilled in the art should recognize that such equivalent embodiments do not depart from the spirit and scope of the present disclosure as described in the appended claims. Brief explanation of the drawing

[0024] The detailed description of the present invention is described below with specific reference to the drawings. Figure 1 illustrates the inhibitor set point versus the supplement source percentage; Figure 2 illustrates the corrosion rate of mild steel; Figure 3 illustrates the copper corrosion rate; FIG. 4 illustrates the calculation of the cycle of concentration; Figure 5 illustrates one embodiment of a cooling tower system. Specific details for implementing the invention

[0025] Various embodiments are described below with reference to drawings in which the same elements are generally referred to by the same reference numerals. The relationships and functions of the various elements of the embodiments may be better understood by referring to the detailed description below. However, the embodiments are not limited to those depicted in the drawings. It should be understood that the drawings are not necessarily drawn to scale and that in certain cases, details not essential to understanding the embodiments disclosed herein, such as ordinary manufacturing and assembly, may be omitted.

[0026] Generally, in scenarios involving multiple supplementary sources, the only practical alternative for the customer is to install a large equalization tank and direct all supplementary streams to it. In such scenarios, only a single water stream originating from the tank is used as cooling tower make-up. This application requires significant capital expenditure and a large footprint for the tank. Furthermore, this tank does not allow the plant to consider how each contributing stream might affect the combined supplementary streams.

[0027] The present disclosure enables monitoring of individual streams without requiring an equalization tank. This also allows the setpoint of corrosion / scale control chemistry to be changed in real time as the ratio of multiple streams entering the cooling tower changes.

[0028] A cooling tower system is disclosed. The cooling system includes a cooling tower; at least two makeup 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 for monitoring water in each of the makeup water inlet streams; and a controller operably connected to at least one sensor.

[0029] Each makeup water inlet stream may have one, two, three, four, five, or six sensors for monitoring the makeup water. The sensors may be configured to detect various characteristics of the makeup water. Examples of characteristics measured by the sensors include, but are not limited to, ORP, dissolved oxygen (DO), conductivity, pH, turbidity, concentration of specific chemicals (e.g., biocides, scale inhibitors, friction reducers, acids, bases, and / or deoxidizers), levels of ions (phosphates) (e.g., determined empirically, automatically, fluorescently, electrochemically, colorimetrically, directly measured, and calculated), temperature, pressure, flow rate, or total dissolved or suspended solids.

[0030] In some embodiments, at least one sensor is a flow sensor. In some embodiments, there are two sensors (a flow sensor and a conductivity sensor) monitoring each supplementary line.

[0031] As another example, the sensor may be an optical sensor that provides measurements indicating the concentration and / or size of particles in the coolant. For example, an optical sensor may be used to measure the turbidity and / or light scattering characteristics of the coolant. An increased concentration of particulates in the coolant may be associated with scale fouling components, which may suggest a scale fouling mechanism. Additionally, or alternatively, an optical sensor may be used to measure fouling formation on the surface of the coolant stream-side of the heat exchanger, or on analogues such as metal coupons or test strips exposed to the same coolant conditions to which the heat exchanger is exposed. The optical sensor may optically evaluate the foulant formed on the monitored surface to determine the characteristics of the foulant and, accordingly, whether the foulant is associated with a scale fouling mechanism (or corrosion or biofouling).

[0032] Corrosion rates can be monitored in makeup water lines and cooling towers. Cooling tower systems include corrosion monitoring technology for copper and mild steel for each stream, and this information can be used to help prevent downstream corrosion problems that may occur in the cooling tower in real time. This is particularly important in applications involving high-efficiency chillers, as the tube walls within the heat exchanger are generally thinner, requiring more careful monitoring of corrosion levels.

[0033] As another example, in a situation where chemical additives are introduced into a coolant stream to counteract potential fouling causes, the additives may include a fluorescently tagged polymer or an inert fluorescent tracer that can be fluorescently analyzed to determine the concentration of the chemical in the coolant. The controller may evaluate the consumption rate of the chemical additives based on the fluorometric response to help determine whether the detected coolant fouling is associated with the fouling mechanism being treated or potentially a different fouling mechanism.

[0034] The term “scale fouling” as used herein refers to fouling of heat exchange surfaces by particulate matter from or formed in cooling water, which includes but is not limited to components such as calcium carbonate, calcium phosphate, magnesium silicate, silica, manganese oxide, aluminum phosphate, soil, and sand.

[0035] The term "corrosion fouling" refers to fouling of heat exchange surfaces by corrosion-formed deposits, such as metal oxides, which can be formed in situ or by failure or redeposition from other parts of the system.

[0036] For example, the evaporation of coolant can lead to the concentration of salts (e.g., calcium, sodium, magnesium) in the coolant stream recycled through the system. These salts can form scale deposits on the surface of the heat exchanger in contact with the coolant. As another example, if the coolant contains organic matter and microorganisms, biofilms may be deposited on the surface of the heat exchanger in contact with the coolant. As an additional example, corrosion products may occur in the coolant stream due to the oxidation of metal components (e.g., iron, aluminum, and / or zinc). These corrosion products may also be deposited on the surface of the heat exchanger in contact with the coolant. Regardless of the mechanism or cause of fouling, the accumulation of a barrier layer on the surface of the heat exchanger in contact with the coolant can reduce the efficiency of heat transfer through the heat exchanger.

[0037] To help reduce or eliminate potential fouling conditions in a cooling water stream passing through a heat transfer network, one or more chemicals may be added to the cooling water to inhibit the formation and / or deposition of fouling. Examples of chemical additives that may be injected into the cooling water include, but are not limited to, polymers (dispersants and scale inhibitors), organophosphorus compounds such as phosphinosuccinic 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 may be injected into the cooling water to control the pH of the cooling water. Examples of pH control agents include mineral acids, organic acids, and inorganic bases.

[0038] The method and system disclosed herein may be scaled to accommodate two or more makeup water streams from independent water sources. In some embodiments, the system comprises three, four, five, or six makeup water inlet streams. Each inlet stream may be connected to a single cooling tower inlet pipe without passing through a makeup water holding tank. Alternatively, each inlet stream may be supplied independently within the cooling tower.

[0039] The cooling system and related processing program will be optimized and adjusted to individual changes in the ratio of the inlet makeup water stream using a pre-determined lookup table stored in the controller.

[0040] Each measured parameter may have a predetermined setpoint or operating range to which the system must be maintained. In some embodiments, the controller stores conductivity, pH, or corrosion setpoints.

[0041] This process of measuring makeup water characteristics and adjusting flow or additive dosage is achieved in real time using Nalco Cooling Water Optimizer, either cloud-based or on-site PLC calculations, enabling real-time or near-real-time control updated to the local PLC.

[0042] The amount of treatment chemicals added may depend on the ratio of the incoming makeup water stream and the resulting water profile.

[0043] Referring to FIG. 5, a cooling tower system ( 100 One implementation example of ) is illustrated. System ( 100 ) is a cooling tower ( 101 ); Cooling tower( 101 At least two makeup water inlet streams configured to supply water to ) 102 ); Cooling tower( 101 A blowdown stream configured to remove water from ) 103 ); supplementary water inlet stream(102 At least one sensor monitoring water in each of ) 104 ); and at least one sensor ( 104 A controller (operably connected to ) 105 Includes ).

[0044] At least two makeup water inlet streams ( 102 ) is a cooling tower ( 101 The pipe connected to ) 107 Connected to ), and pipe( 107 ) has at least two makeup water inlet streams ( 102 cooling tower () from ) 101 It transports water into the cooling tower. The replenishment stream does not need to be connected to the pipes that transport water to the cooling tower, but can be directly connected to the cooling tower to deliver replenishment water.

[0045] The cooling tower system is a distributed control system operablely connected to a controller ( 108 It may include ). PLC controller ( 105 ) is a supplementary water stream sensor ( 104 Receives input from ). The PLC controller is an optimizer ( of any combination of makeup water streams. 109 It is pre-programmed to generate a virtual composite stream using ) performance data. PLC controller( 105 ) will position appropriate control parameters according to the virtual composite stream replenishment ratio. The control parameters are the controller( 110 ) and distributed control system( 108 It is sent to ) to activate the chemical pump and blowdown valve. The control parameters are not sent to all locations, but are sent only to the locations that control the blowdown valve and the chemical pump.

[0046] In a cooling tower, water evaporates ( 111 It is lost through ), and makeup water must be added. The fluid is in the heat exchanger ( 113 On the way to ), line(117 filter() through ) 112 It moves through the ). Afterwards, the fluid moves through the cooling tower ( 101 Returns to ). line( 117 The fluid within the line( 114 It can be treated with chemicals by injecting the preparation through ). Replenishment water line ( 102 ) is also a line( 114 supplementary water line () through ) 102 in ) or cooling tower( 101 It can be treated with chemical additives by injecting directly into the tank. The chemical is in the tank ( 115 It can be stored in ) and pumped into the target line.

[0047] line( 117 A sample of the fluid within the line( 116 Extracted using ) and water analysis unit ( 110 It can be analyzed using ). line( 117 The characteristics of the fluid within ) are the controller( 110 It can be transmitted to ), where the characteristic can be compared with the stored setpoint. Controller( 110 ) subsequently determines whether adjustments should be made to the makeup water flow rate or the amount of chemical additives injected. The makeup water sensor is the PLC controller ( 105 Reported in ), and based on the replenishment ratio of the composite stream, the controller ( 110 Outputs a control parameter corresponding to ).

[0048] In a specific embodiment, the control system includes a monitoring and control unit comprising a controller and a plurality of sensors. Each of the plurality of sensors can communicate with the controller. For example, if the unit includes five sensors, each of the five sensors can communicate with the controller. In a specific embodiment, the controller may be attached to a skid or other type of support member so as to be movable.

[0049] A method for controlling cooling water treatment is also provided. The method includes the steps of: 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 generating a virtual makeup stream from the data received from at least one sensor.

[0050] A virtual replenishment stream refers to a stream composed of a specific ratio of replenishment water inlet streams. Based on the characteristics of each replenishment water stream, such as flow rate and conductivity, the characteristics of the mixed stream can be predicted when two or more replenishment streams are mixed.

[0051] Sensor reception data for the makeup water inlet stream is analyzed and a virtual stream is generated. The amount of chemical additives and the blowdown flow rate can be adjusted based on the characteristics of the virtual stream.

[0052] In some embodiments, the method may include the step of controlling the blowdown and CoC (concentration cycle) of the cooling system based on changes in the quality of the makeup water stream.

[0053] As used herein, the term “controller” refers to an electronic device or manual operator having components such as a processor, a memory device, a digital storage medium, a communication interface comprising a communication circuit operable to support communication across any number of communication protocols and / or networks, a user interface (e.g., a graphical user interface that may include a cathode ray tube, a liquid crystal display, a plasma display, a touch screen, or other monitor), and / or other components.

[0054] The controller is preferably operable for integration with one or more application-specific semiconductors, programs, computer-executable instructions or algorithms, one or more hard-wired devices, wireless devices, and / or one or more mechanical devices. Furthermore, the controller is operable to integrate the feedback, feed-forward, and / or prediction loop(s) of the present invention. Some or all of the functions of the controller system may be located at a central location, such as a network server, for communication via a local area network, a wide area network, a wireless network, an internet connection, a microwave link, an infrared link, and a wired network (e.g., Ethernet). Additionally, other components, such as a signal conditioner or a system monitor, may be included to facilitate signal transmission and signal-processing algorithms.

[0055] In certain embodiments, the controller includes hierarchical logic that prioritizes any measured or predicted characteristics associated with system parameters. For example, the controller can 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 prevent circular control loops.

[0056] In some embodiments, the monitoring and control unit and the associated method include an automated controller. In some embodiments, the controller is manual or semi-manual. For example, if the system includes one or more datasets received from various sensors in the system, the controller may automatically determine which data points / datasets to further process, or an operator may make such determination partially or entirely. For example, a dataset for industrial water may include variables or system parameters such as ORP, dissolved oxygen (DO), conductivity, pH, turbidity, concentrations of specific chemicals (e.g., biocides, scale inhibitors, acids, bases), ion levels (e.g., determined empirically, automatically, fluorescently, electrochemically, colorimetrically, directly measured, and calculated), temperature, pressure, flow rate, total dissolved or suspended solids, etc. Such system parameters are typically measured using any type of suitable data capture 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 capture equipment communicates with a controller and, depending on some embodiments, may have advanced functions provided by the controller (including any part of the control algorithms described herein).

[0057] The monitoring and control unit may include a plurality of sensors capable of analyzing water and transmitting data regarding the water to a controller. The plurality of sensors may include, for example, sensors for measuring conductivity, pH, ORP, biocide concentration, turbidity, temperature, flow, 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, and one or more additional sensors not specifically mentioned herein, and the sensors may communicate with the controller. Other types of sensors considered by the present disclosure include, but are not limited to, oil-in-water sensors, total dissolved solids sensors, and total suspended solids sensors.

[0058] The monitoring and control system disclosed herein includes, in certain embodiments, one or more chemical injection pumps. Each chemical injection pump may fluidly communicate with a storage device. Each storage device may contain one or more chemicals, and the chemical injection pump may transport such chemicals to a body of water. In some embodiments, the chemical injection pump includes a storage device. The chemical injection pump may communicate with a controller in any number of ways, such as electronically, cellularly, via infrared, satellite, or according to any other type of communication network, topology, protocol, and standard, etc., e.g., through wired connections, any combination of wireless connections. Accordingly, the controller may transmit a signal to the pump to control its chemical supply rate.

[0059] In a specific embodiment, the monitoring and control system is implemented with a plurality of sensors that provide continuous or intermittent feedback, feed-forward, and / or predictive information to the controller, and the controller may relay this information to a relay device, e.g., Nalco Global Gateway, and the relay device may transmit the information via cellular communication to a remote device, e.g., a mobile phone, a computer, and / or any other device capable of receiving cellular communication. The remote device may interpret the information and automatically transmit a signal (e.g., an electronic command) back to the controller via the relay device so that the controller may perform a specific adjustment of the pump output. The information may also be processed internally by the controller, and the controller may automatically transmit a signal to the pump, for example, to adjust the amount of chemical injection. Based on the information received by the controller from the plurality of sensors or remote devices, the controller may transmit a signal to various pumps to perform real-time automatic adjustment of the amount of chemical being injected into the water by the pumps.

[0060] Alternatively, an operator of a remote device receiving cellular communication from a controller may manually operate the pump via the remote device. The operator may transmit commands to the controller via the remote device, either cellularly or otherwise, and the controller may adjust the chemical addition rate of the chemical injection pump. For example, the operator may receive a signal or alarm from the remote device via cellular communication from the controller and use the remote device to transmit commands 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 perform any combination of the above. The controller and / or the remote device may also automatically perform any of the aforementioned adjustments or modifications without the operator actually transmitting or inputting any commands. Preset parameters or programs are input into the controller or the remote device, and accordingly, the controller or the remote device may determine whether the measured characteristics are outside an acceptable range. Based on information received by multiple sensors, the controller or remote device can perform appropriate adjustments to the pump or send appropriate alarms.

[0061] In a specific embodiment, the remote device or controller includes appropriate software for receiving data from a plurality of sensors and can determine whether the data indicates that one or more measured characteristics of the water are within or outside an acceptable range. The software can also enable the controller or remote device to determine appropriate measures to be taken to correct characteristics that are outside the acceptable range. For example, if the measured pH exceeds the acceptable range, the software enables the controller or remote device to make such a determination and to take corrective measures, such as sounding an alarm to a pump to increase the flow of acid into the water body.

[0062] The monitoring and control system and / or controller disclosed herein may include programming logic for converting analyzer signals from a plurality of sensors into pump control logic and, in certain embodiments, controlling one or more of a plurality of chemical injection pumps by a specific criterion. Non-limiting exemplary examples of the types of chemical injection pumps that may be operated include chemical injection pumps that serve to inject biocides, scale inhibitors, friction reducers, acids, bases, sulfites, deoxidizers, and any other type of chemical that may prove useful for certain aqueous industrial systems. Specific examples of biocides, scale inhibitors, friction reducers, acids, bases, sulfites, and deoxidizers are all well known in the art, and all examples of such chemicals are within the scope of this disclosure.

[0063] The sensors disclosed herein are operable to detect and / or predict properties associated with water or system parameters and to convert the properties into input signals, e.g., electrical signals, which can be transmitted to a controller. A transmitter associated with each sensor transmits the input signals to the controller. The controller is operable to receive the transmitted input signals, convert the received input signals into input values, analyze the input values ​​to determine whether the input values ​​are within an optimal range, generate output values, convert the output values ​​into output signals, e.g., electrical signals, and transmit the output signals to a receiver, e.g., a pump having such receiver functions, or to a remote device such as a computer or mobile phone having receiver functions. The receiver may be operable to receive the output signals and issue an alarm to an operator to regulate the flow rate of the pump, or the receiver may be operable to automatically cause a change in the flow rate of the pump if the output values ​​are not within an acceptable range for such properties.

[0064] The method is optionally repeated for multiple different system parameters, each of which has unique associated characteristics, or alternatively, all system parameters can be analyzed simultaneously by multiple sensors.

[0065] Data transmission of measured parameters or signals to chemical pumps, alarms, remote monitoring devices, such as computers or mobile phones, or other system components is performed using any suitable device and through any number of wired and / or wireless networks, including, for example, WiFi, WiMAX, Ethernet, cable, digital subscriber lines, Bluetooth, cellular technologies (e.g., 2G, 3G, UMTS (Universal Mobile Telecommunications System), GSM, Long Term Evolution (LTE), etc.). Nalco Global Gateway is an example of a suitable device. Any suitable interface standard(s), such as Ethernet interfaces, wireless interfaces (e.g., IEEE 802.11a / b / g / x, 802.16, Bluetooth, optical, infrared, other radio frequencies, etc.), universal serial buses, telephone networks, etc., and combinations of these interfaces / connections may be used.

[0066] As used herein, the term "network" includes all such data transmission methods. Any of the described devices (e.g., archiving systems, data analysis stations, data capture devices, process devices, remote monitoring devices, chemical injection pumps, etc.) may be connected to one another using the aforementioned or other suitable interfaces or connections.

[0067] In some embodiments, system parameter information is received from and archived from the system. 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 in real time. Such real-time reception may include, for example, "streaming data" over a computer network.

[0068] The method disclosed herein can be used in various applications. For example, the oxidizing composition can be used as a sacrificial oxidizing agent to reduce the demand for converted chlorine dioxide molecules, and in non-biocidal applications where hypochlorite is a limitation, this approach can enable the use of chlorine dioxide in freshwater or influent treatment, in wastewater treatment where certain species of pollutants may require oxidation, in water streams with chemically reducing environments, to create an aerobic environment in water streams with significant anaerobic environments, in water systems where high doses of oxidizing biocides can have harmful effects but low doses can be beneficial, and in open-loop recirculating cooling water systems in the food and beverage industry, paper processes, and mining.

[0069] Examples

[0070] Example 1

[0071] The scenario tested for the present invention consists of three makeup water streams, each having two sensors (flow and conductivity) in each makeup water stream. The makeup water sensors are connected to a PLC controller that accepts flow and conductivity inputs for each individual makeup stream. A virtual composite stream is created, and control parameters for this specific virtual composite stream are output to a distribution control screen and a cooling tower controller. The distribution control screen controls a blowdown valve, and the cooling tower controller controls a chemical pump and a conductivity setpoint.

[0072] FIG. 1 illustrates the flow rate change and blending conditions from the first stream to the second stream. At this stage of the experiment, the inventors also verified the modification of the blend ratio and the modification of the chemical setpoint. It clearly illustrates that as the virtual composite stream fluctuates based on the loading and cooling tower levels, the programming outputs corresponding control parameters to protect the system.

[0073] As mentioned in FIGS. 2 and 3, the instantaneous mild steel corrosion (Fig. 2) and copper corrosion (Fig. 3) rates are maintained within specifications. Although the corrosiveness of the replenishment stream affects the instantaneous corrosion rate of the system water, the system remains protected because the control can be modified based on the replenishment ratio.

[0074] The concentration cycle and tower system conductivity are illustrated in Fig. 4. This illustrates the changing concentration cycle, as the reader's virtual composite stream of makeup water raises or lowers the concentration cycle by continuously changing the conductivity. The reduction in tower conductivity is intended to protect the system based on the makeup water ratio. As more corrosive water is introduced into the system, the conductivity is reduced to protect the system.

[0075] All compositions and methods disclosed and claimed herein can be manufactured and practiced without excessive experimentation in light of the present disclosure. Although the present invention may be embodied in a number of different forms, specific preferred embodiments of the present invention are described in detail herein. The present disclosure is an example of the principles of the present invention and is not intended to limit the present invention to the specific embodiments illustrated. Furthermore, unless otherwise clearly indicated, the use of the singular form is intended to include "at least one" or "one or more." For example, "sensor" is intended to include "at least one sensor" or "one or more sensors."

[0076] Any range given in absolute or approximate terms is intended to include both, and any definitions used herein are for clarity and are not intended to be limiting. Although numerical ranges and parameters presenting the broad scope of the invention are approximate, the figures presented in specific examples are reported as accurately as possible. However, any figures inherently include certain errors inevitably caused by the standard deviation found in each of their respective test measurements. Furthermore, all ranges disclosed herein are understood to include any and all sub-ranges contained therein (including all fractional and integer values).

[0077] Any composition disclosed herein may include, be made of, or essentially made of any element, component and / or component disclosed herein, or any combination of two or more of the element, component or component disclosed herein.

[0078] Any method disclosed herein may include, be composed of, or essentially composed of any method step disclosed herein or any combination of two or more of the method steps disclosed herein.

[0079] The conjunction "comprising," which is synonymous with "including," "containing," or "characterized by," is comprehensive or open and does not exclude additional, unmentioned elements, components, elements, and / or method steps.

[0080] The connecting phrase "consisting of" excludes any element, component, part, and / or method step not specified in the claim.

[0081] The linking phrase "essentially consisting of" limits the claim category to those that do not substantially affect the specified elements, components, elements, and / or steps, as well as the basic and novel feature(s) of the claimed invention.

[0082] Unless otherwise specified, all molecular weights mentioned herein are weight-average molecular weights, and all viscosities were measured at 25°C using pure (undiluted) polymers.

[0083] The term “about” as used herein refers to a mentioned value within the error resulting from the standard deviation found in each of its test measurements, and where such error cannot be measured, “about” may indicate, for example, within 5% of the mentioned value.

[0084] Furthermore, the present invention includes any and 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 may be made without departing from the spirit and scope of the invention and without diminishing its intended benefits. Accordingly, such changes and modifications are intended to be included by the appended claims.

[0085] explanation

[0086] Description 1: A cooling tower system comprising: a cooling tower; at least two makeup 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 for monitoring water in each of the makeup water inlet streams; and a controller operably connected to at least one sensor.

[0087] Description 2: In Description 1, the system comprises at least two makeup water inlet streams, including three makeup water inlet streams.

[0088] Description 3: A system in any one of Descriptions 1 to 2, wherein at least two makeup water inlet streams are connected to a pipe connected to a cooling tower, and the pipe carries water from at least two makeup water inlet streams into the cooling tower.

[0089] Description 4: A system in which, in any one of Descriptions 1 to 3, at least one sensor is a conductivity sensor.

[0090] Description 5: A system in which, in any one of Descriptions 1 to 3, at least one sensor is a flow sensor.

[0091] Description 6: A system in any one of Descriptions 1 to 5, wherein each supplementary water inlet stream is monitored by at least two sensors.

[0092] Description 7: In Description 6, the system, wherein at least two sensors are a conductivity sensor and a flow sensor.

[0093] Description 8: In any one of Descriptions 1 to 7, the controller stores a conductivity setpoint, in a system.

[0094] Description 9: A system comprising, in any one of Descriptions 1 to 8, a distributed control system operably connected to a controller.

[0095] Description 10: A system in any one of Descriptions 1 to 9, wherein the system does not include a makeup water holding tank configured to supply water to a cooling tower.

[0096] Description 11: A method for controlling cooling water treatment, comprising the steps of: 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 generating a virtual makeup stream from the data received from at least one sensor.

[0097] Description 12: Method of Description 11, wherein at least one sensor is a conductivity sensor.

[0098] Description 13: The method of Description 11, wherein at least one sensor is a flow sensor.

[0099] Description 14: A method in any one of Descriptions 11 to 13, wherein data is received from at least three sensors monitoring water in three supplementary water inlet streams.

[0100] Description 15: A method comprising, in any one of Descriptions 11 to 14, further adding a chemical additive to a cooling tower based on the characteristics of a virtual supplement stream.

[0101] Description 16: A method comprising, in any one of Descriptions 11 to 15, further a step of controlling the blowdown based on the characteristics of a virtual supplementary stream.

[0102] Description 17: A method comprising, in any one of Descriptions 11 to 16, further a step of monitoring the corrosion rate of copper and / or mild steel in a supplementary water inlet stream.

[0103] Description 18: A method in which, in any one of Descriptions 11 to 17, each supplementary water inlet stream is monitored by at least two sensors.

[0104] Description 19: The method of Description 15, wherein the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and any combination thereof.

[0105] Description 20: A method comprising, in any one of Descriptions 11 to 19, further a step of adjusting the ratio of supplementary water in the first stream to supplementary water in the second stream.

Claims

Claim 1 A cooling tower system comprising: a cooling tower; at least two makeup 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 for monitoring water in each of the makeup water inlet streams; and a controller operably connected to the at least one sensor, wherein the controller is configured to receive data from the at least one sensor, generate a virtual composite stream which is a mixed stream of the at least two makeup water inlet streams from the data received from the at least one sensor, and control cooling water treatment based on at least one predicted characteristic of the virtual composite stream. Claim 2 A system according to claim 1, wherein the at least two supplementary water inlet streams comprise three supplementary water inlet streams. Claim 3 A system according to claim 1, wherein the at least two supplementary water inlet streams are connected to a pipe connected to the cooling tower, and the pipe carries water from the at least two supplementary water inlet streams into the cooling tower. Claim 4 A system according to claim 1, wherein at least one sensor is a conductivity sensor. Claim 5 A system according to claim 1, wherein at least one sensor is a fluid sensor. Claim 6 A system according to claim 1, wherein each supplementary water inlet stream is monitored by at least two sensors. Claim 7 In claim 6, the system wherein the at least two sensors are a conductivity sensor and a flow sensor. Claim 8 In paragraph 1, the controller is a system that stores a conductivity setpoint. Claim 9 A system according to claim 1, further comprising a distributed control system operablely connected to the controller. Claim 10 A system according to claim 1, wherein the system does not include a supplementary water holding tank configured to supply water to the cooling tower. Claim 11 A method for controlling cooling water treatment, 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; generating a virtual composite stream, which is a mixed stream of at least two makeup water inlet streams, from the data received from the at least one sensor; and controlling cooling water treatment based on at least one predicted characteristic of the virtual composite stream. Claim 12 A method according to claim 11, wherein at least one sensor is a conductivity sensor. Claim 13 In paragraph 11, the method wherein at least one sensor is a fluid sensor. Claim 14 In paragraph 11, the method wherein data is received from at least three sensors monitoring water in three supplementary water inlet streams. Claim 15 A method according to claim 11, further comprising the step of introducing a chemical additive into the cooling tower based on the characteristics of the virtual composite stream. Claim 16 A method according to claim 11, further comprising the step of controlling blowdown based on the characteristics of the virtual composite stream. Claim 17 A method according to claim 11, further comprising the step of monitoring the corrosion rate of copper and / or mild steel in the supplementary water inlet stream. Claim 18 In paragraph 11, a method in which each supplementary water inlet stream is monitored by at least two sensors. Claim 19 In paragraph 15, the chemical additive is selected from the group consisting of scale inhibitors, corrosion inhibitors, biocides, dispersants, and any combination thereof. Claim 20 A method according to claim 11, further comprising the step of adjusting the ratio of supplementary water in the first stream to supplementary water in the second stream.

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