Cooling Tower Deficiency Detection via Sensor Disparity Analysis
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Solution Overview
Problem
Current methods for monitoring cooling tower performance in thermal facilities are inefficient and lack real-time detection capabilities, leading to delayed identification of deficiencies and associated power losses, as they rely on costly and time-consuming ad hoc tests that are not typically implemented for ongoing monitoring.
Innovation Solution
A method involving continuous measurement of physical parameters by sensors, data processing to calculate expected optimum values, and determination of potentially deficient functions within the cooling tower, with alarm triggering for identified deficiencies, utilizing a system with sensors, data processing means, and a reference database to assess disparities and variations in performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ad hoc thermal performance tests are carried out according to standards EN 14705 or ISO 16345, then measurement precision of cooling tower performance is improved, but loss of time and productivity are worsened due to test duration of around one week and extensive logistics
Solution Approach 1:
The patent replaces the mechanical/physical test system with extensive logistics and manual measurements with an automated electronic monitoring system that continuously measures temperature, flow rate, and power consumption parameters. Sensors and data processing means automatically track cooling tower performance without requiring physical test setups or manual intervention, thus eliminating the time-consuming logistics while maintaining measurement precision.
Solution Approach 2:
The patent implements continuous monitoring of cooling tower performance parameters throughout operation, rather than performing discrete periodic tests. The system continuously measures inlet and outlet temperatures, water flow rates, and power consumption, providing ongoing performance data that enables real-time detection of efficiency losses without stopping operations or scheduling lengthy test periods.
2Measurement precision
If ad hoc thermal performance tests are carried out according to standards EN 14705 or ISO 16345, then measurement precision of cooling tower performance is improved, but device complexity and cost are worsened due to extensive logistics for managing all phases of the test
Solution Approach 1:
The monitoring system is designed to automatically perform all measurement and analysis functions without external intervention. Sensors self-measure temperature and flow parameters, the data processing means automatically calculates performance metrics, and the system autonomously detects deficiencies and generates alerts. This eliminates the need for external test teams, equipment setup, and manual data collection, thereby reducing device complexity and cost while maintaining measurement precision.
Solution Approach 2:
The monitoring system integrates multiple measurement functions into a single unified platform that simultaneously tracks temperature, flow rate, power consumption, and performance efficiency. This multi-functional system replaces multiple separate test equipment and procedures required by traditional standards, simplifying the overall system while maintaining comprehensive measurement capabilities.
3Reliability
If cooling tower performance is monitored using traditional methods, then detection of deficiencies is achieved, but loss of time in identifying failures and their origin is worsened
Solution Approach 1:
The system continuously feeds back performance data from sensors to the data processing means, which immediately analyzes temperature differences, flow rates, and power consumption to detect deficiencies. When performance deviations are detected, the system automatically generates alerts and identifies potential causes, providing rapid feedback that enables immediate corrective action without the delayed analysis inherent in traditional periodic testing methods.
4Measurement precision
If cooling tower performance tests are carried out periodically, then performance evaluation is achieved, but productivity loss from power plant output reduction is worsened during test periods
Solution Approach 1:
The monitoring system operates continuously during normal power plant operations, measuring performance parameters without interrupting the cooling tower or power generation processes. This eliminates the need to reduce power plant output or schedule dedicated test periods, maintaining full productivity while continuously evaluating performance accuracy through real-time data collection and analysis.
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
Enables efficient, objective monitoring of cooling tower performance, allowing for rapid detection of failures, identification of their origin, and quantification of losses, thereby optimizing maintenance operations and preventing power plant shutdowns.
Implementation Method 1
Measurement, by a plurality of sensors, of a set of values of physical parameters relating to the cooling tower
Implementation Method 2
Part of the water is going to evaporate, which favours the exchange of heat and improves the cooling of the water
Implementation Method 3
The function of cooling towers is to evacuate, to the surrounding medium, heat from the condenser by making hot water circulate in an air flow
Data Source
AI summary
The invention relates to a method for detecting deficiencies in a cooling tower (2) of a thermal facility (1) in operation in a given environment, comprising the implementation of the steps of:(a) measurement, by a plurality of sensors (13), of a set of values of physical parameters relating to the cooling tower (2), at least one of which being an endogenous parameter specific to the operation of the cooling tower (2) and at least one exogenous parameter specific to said environment;(b) calculation, by data processing means (11), of at least one expected optimum value of said endogenous parameter as a function of said values of the physical parameters and a model;(c) determination, by the data processing means (11), of at least one potentially deficient function of the cooling tower (2) as a function of the disparity between the measured value and the expected optimum value of said endogenous parameter and/or the variation of said disparity;(d) testing, by the data processing means (11), of each function of the cooling tower (2) determined as being potentially deficient; and(e) triggering of an alarm, by the data processing means (11), if at least one function of the cooling tower (2) is evaluated as being deficient in the test.