Water Temperature Monitoring
Monitor inlet (hot water) and outlet (cold water) temperatures.
Evaluate overall cooling tower efficiency and performance.
Detect heat load changes in process or chiller return water.
Identify fouling or scale buildup reducing heat transfer.
Optimize fan and pump operation based on real-time temperature trends.
Water Flow Monitoring
Verify proper flow rate through cooling tower and condenser loops.
Detect blockages, pump failures, or valve restrictions.
Ensure balanced flow between multiple cooling towers.
Monitor flow for energy optimization and load balancing.
Detect air entrainment or cavitation issues in pumps.
Air Temperature and Humidity Monitoring
Measure ambient air conditions for performance calculation (wet-bulb temperature).
Track seasonal or environmental effects on tower efficiency.
Monitor humidity to optimize evaporation rate and fan operation.
Detect conditions that may cause scaling or poor cooling performance.
Support automatic fan speed and water flow control strategies.
Vibration Monitoring
Monitor fan and motor vibration for imbalance or bearing wear.
Detect gearbox misalignment or blade damage.
Identify looseness in fan shaft couplings or supports.
Prevent costly failures and extend fan motor life.
Enable predictive maintenance alerts before mechanical failure.
Fan Motor Electrical Monitoring
Measure power consumption for energy management.
Detect overloads, motor imbalance, or phase loss.
Track operating cycles and motor runtime.
Identify efficiency losses due to bearing wear or fan drag.
Enable remote monitoring of fan status and performance.
Water Level Monitoring
Monitor basin or sump water levels for proper operation.
Prevent pump cavitation due to low-level conditions.
Detect overflow or excessive fill levels.
Support automatic makeup water control.
Protect pumps and components from dry running.
Water Quality Monitoring
Measure water conductivity to control dissolved solids (TDS).
Monitor pH balance to prevent scaling or corrosion.
Track oxidation-reduction potential (ORP) for disinfection effectiveness.
Detect contamination or debris buildup in recirculating water.
Ensure compliance with water treatment and environmental standards.
Differential Pressure Monitoring
Detect clogging across strainers, filters, or heat exchangers.
Identify scaling or fouling on condenser tubes.
Verify clean flow paths for optimal cooling efficiency.
Support preventive maintenance by alerting when filters need cleaning.
Reduce downtime caused by restricted flow conditions.
Make-Up and Blowdown Control Monitoring
Monitor make-up water flow to maintain correct basin levels.
Control blowdown cycles based on water conductivity.
Prevent excessive water waste or over-concentration of minerals.
Optimize chemical treatment and water usage efficiency.
Reduce operational costs through automated control logic.
Ambient Environmental Monitoring
Measure outdoor conditions impacting cooling tower performance.
Detect high wind speeds that can cause water drift or loss.
Monitor air quality around the tower for maintenance planning.
Track seasonal trends to adjust cooling tower operation.
Optimize system control based on environmental data.
Structural & Safety Monitoring
Monitor tower structure for excessive vibration or movement.
Detect corrosion or degradation in steel or concrete components.
Track support frame stress levels under load.
Ensure operational safety in harsh or aging installations.
Support predictive maintenance and structural inspection schedules.
System Performance & Analytics
Calculate cooling efficiency (∆T between inlet and outlet water).
Monitor fan speed vs. temperature for optimization.
Track energy usage vs. cooling output (kW/ton performance).
Predict maintenance needs based on trend analysis.
Generate performance reports and system health summaries.