Cooling Tower Blowdown Control Using Flow Threshold Feedback
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Solution Overview
Problem
Existing systems for adjusting conductivity and chemical parameters in cooling tower hydraulic circuits are prone to errors due to malfunctioning solenoid valves and inadequate flow control, leading to potential corrosion, deposit formation, and increased maintenance costs.
Innovation Solution
A method and system that utilize flow sensors to monitor and control the discharge and replenishment operations in the cooling tower, ensuring that the discharge operation is only permitted when a preset flow rate is maintained, and inhibiting operations if flow rates fall below threshold values to prevent damage and maintain optimal chemical parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If prior art systems use solenoid valves for discharge operations controlled by time duration, then the discharge operation can be automated, but the system is prone to errors when solenoid valves malfunction or deposits block flow
Solution Approach 1:
The patent implements feedback control by using flow sensors to continuously monitor the actual flow rate during discharge operations. The control unit compares the detected flow rate with the preset flow rate and adjusts the discharge operation accordingly, ensuring the actual discharge matches the intended discharge even when solenoid valves malfunction or deposits block flow.
Solution Approach 2:
The patent replaces the mechanical/time-based control system with an electronic sensor-based control system. Instead of relying on solenoid valves and time duration settings, the system uses flow sensors to detect actual flow conditions and electronically controls the discharge operation, eliminating the unreliability of mechanical components.
2Device complexity
If prior art systems control discharge based on preset time duration, then the control logic is simple, but the actual outflow may not correspond to the discharge signal causing system damage
Solution Approach 1:
The control unit receives feedback from flow sensors that continuously monitor the actual flow rate. This feedback loop allows the system to adjust the discharge operation in real-time to match the preset flow rate requirements, ensuring precise control without complex manual calculations or multiple control stages.
Solution Approach 2:
The system automatically adjusts the discharge operation based on real-time flow detection without requiring external intervention or complex control algorithms. The flow sensors and control unit work together to self-regulate the discharge process, maintaining precision while keeping the control logic relatively simple.
3Device complexity
If prior art systems interrupt all dosages during discharge interruption, then the control system is simplified, but pH and chlorine adjustment devices also stop dosing causing parameter deviations
Solution Approach 1:
The patent segments the control of different devices independently. The flow sensor controlling unit specifically controls only the discharge operation and replenishment water flow based on flow rate detection, while the dosing devices (pH and chlorine adjustment) continue their normal operation unaffected by discharge interruptions. This segmentation allows precise control of discharge without unnecessarily interrupting other critical functions.
Solution Approach 2:
The control system applies different control strategies to different parts of the system. The discharge operation receives flow-rate-based control to prevent damage, while the dosing devices maintain their own independent control to ensure continuous chemical parameter adjustment. This local differentiation of control quality ensures each subsystem operates optimally for its specific function.
4Reliability
If the system uses flow sensors to monitor discharge operations, then the reliability of discharge control is improved, but the device complexity increases
Solution Approach 1:
The flow sensors provide continuous feedback to the control unit, which automatically adjusts the discharge operation to match preset parameters. This feedback mechanism improves reliability by ensuring actual discharge matches intended discharge, while the automated nature of the feedback loop prevents significant increases in operational complexity.
Solution Approach 2:
The control unit acts as an intermediary between the flow sensors and the discharge solenoid valve. It processes the sensor signals and translates them into appropriate control actions, simplifying the overall system architecture while maintaining high reliability through centralized intelligent control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the likelihood of errors in hydraulic circuit adjustments, automatically controls dispensing devices, minimizes the need for external operators, and reduces maintenance costs by ensuring accurate chemical product introduction and maintaining the integrity of the hydraulic circuit.
Implementation Method 1
detecting a flow rate of liquid flowing between an inlet mouth and a discharge mouth of the collection tank
Implementation Method 2
the liquid phase, during the fall, to transfer energy to a gaseous phase thus reducing its own temperature. In fact, water cooling is obtained favoring the evaporation of a small amount of the water itself
Implementation Method 3
transfer energy to a gaseous phase thus reducing its own temperature
Data Source
AI summary
An adjusting method to adjust the liquid discharge operation from a collection tank of a cooling tower, comprising the steps of: checking an activation signal of a discharge solenoid valve (EV) of the tank; detecting a flow value of the liquid flowing between an inlet mouth and a discharge mouth of the collection tank to allow a discharge operation of the liquid contained in the tank, wherein said discharge operation is allowed in correspondence of a detection of a flow rate value of the liquid flowing between an inlet mouth and a discharge mouth of the collection tank at least equal to a reference threshold value and wherein said discharge operation is inhibited in correspondence of a detection of the liquid flow rate value that is null or lower than said reference threshold value.