Cooling tower manufacturers
How to adjust the cooling water volume in real time based on the cooling tower’s operating data and enviro
How to adjust the cooling water volume in real time based on the cooling tower’s operating data and environmental monitoring to ensure optimal performance and energy saving?
The following is a specific method to adjust the cooling water volume in real time based on the cooling tower's operating data and environmental monitoring to ensure optimal performance and energy saving:
1. Collect key operating data and environmental monitoring data
Cooling tower operating data:
Inlet and outlet water temperature: The temperature sensors installed on the cooling tower's inlet and outlet pipes accurately measure the temperature of the cooling water when it enters and flows out of the cooling tower. This is the most direct data reflecting the cooling effect of the cooling tower. For example, if the inlet water temperature is 37°C and the outlet water temperature is expected to drop to 32°C, the actual monitored outlet water temperature is higher or lower than this value, indicating that the cooling water volume and other parameters may need to be adjusted.
Cooling water flow rate and flow rate: Use a flow meter installed on the cooling water pipeline to monitor the cooling water flow rate in real time (usually in cubic meters per hour, m³/h). The flow rate can be calculated based on information such as the flow rate and the cross-sectional area of the pipeline. Understand the current cooling water volume to provide basic reference data for subsequent adjustments, and compare it with the design flow rate to determine whether there is an abnormality.
Fan operation status: including parameters such as fan speed, current, and power. Fan speed affects the air flow rate, which in turn affects the heat exchange efficiency of the cooling tower. For example, a reduction in speed may lead to insufficient air flow, affecting the cooling effect. At this time, it may be necessary to adjust the cooling water volume to compensate.
Pump operation parameters: such as the pump head, flow, power, and working pressure. The pump is responsible for transporting cooling water to the cooling tower for cooling. Its operating status is closely related to the cooling water volume. If the pump fails or its performance deteriorates, resulting in abnormal water supply, it also needs to be adjusted in time.
Environmental monitoring data:
Ambient temperature: Install meteorological temperature sensors around the cooling tower to obtain real-time ambient temperature data (in degrees Celsius, ℃). An increase in ambient temperature will reduce the temperature difference between the cooling tower and the outside air, affecting the heat exchange efficiency, and may require an increase in cooling water volume; conversely, the water volume can be appropriately reduced when the temperature drops.
Air humidity: The relative humidity of the air (expressed as a percentage) is monitored by a humidity sensor. In a high humidity environment, water is difficult to evaporate, and the evaporative cooling effect is limited. It is often necessary to increase the amount of cooling water; in a low humidity environment, the amount of water can be reduced accordingly to optimize the cooling process.
Wind speed and direction: The wind speed (usually in meters per second, m/s) and wind direction at the location of the cooling tower are monitored with the help of an anemometer. Appropriate wind speed can promote heat exchange and the amount of water can be appropriately reduced; unfavorable wind direction may cause problems such as hot air backflow, affecting the cooling effect. At this time, it may be necessary to increase the amount of water or take other countermeasures, such as adjusting the operation mode of the cooling tower.
Atmospheric pressure: For cooling towers at different altitudes or in areas with special meteorological conditions, atmospheric pressure (usually in Pascals, Pa) data is also very important. Changes in atmospheric pressure will affect the boiling point of water and air density, and thus affect the cooling process of the cooling tower. However, atmospheric pressure is usually relatively stable, and its impact on the adjustment of cooling water volume only needs to be considered in special circumstances.
2. Establish a data analysis and decision-making mechanism
Set target parameters and thresholds:
According to the design performance of the cooling tower and the operating requirements of the equipment it serves (such as industrial heat exchange equipment, air conditioning chillers, etc.), set reasonable target outlet water temperature, cooling water volume range corresponding to the best cooling efficiency and other key target parameters. At the same time, set corresponding thresholds for various operating data and environmental data. For example, the normal fluctuation range of the inlet and outlet water temperature difference is set to ±2℃. When it exceeds this range, it is necessary to analyze the cause and consider adjusting the cooling water volume; for example, when the ambient humidity exceeds 80%, it is suggested that the cooling water volume may need to be increased to maintain the cooling effect.
Data analysis method:
Comparative analysis: Compare the real-time collected operating data with historical data and design standard data of the same period to see if there are any abnormal deviations. For example, if the current cooling water flow rate is 10% lower than the normal design flow rate, and the outlet water temperature is 3℃ higher than normal, it is likely that the cooling water volume needs to be increased to restore the normal cooling effect.
Trend analysis: Observe the changing trend of various data over time, predict possible problems in advance and make timely adjustments. For example, if the ambient temperature is gradually rising and is expected to continue to rise, the cooling water volume can be gradually increased in advance based on past experience and correlation analysis of heat exchange principles to avoid a sharp drop in cooling effect due to temperature rise, which may affect subsequent equipment operation.
Correlation analysis: Analyze the correlation between different data, such as the possible causal relationship between the decrease in fan speed and the increase in outlet water temperature, because insufficient fan speed will reduce air flow and affect heat exchange. In addition to checking fan failure, it may also be necessary to increase the cooling water volume appropriately to maintain the cooling effect until the fan resumes normal operation.
3. Strategies and methods for adjusting cooling water volume in real time
Adjustment strategies based on temperature changes:
Rising inlet water temperature: When the inlet water temperature of the cooling tower is detected to rise, first determine whether it is caused by an increase in the heat load on the equipment side or environmental factors (such as rising ambient temperature, hot air reflux, etc.). If the reason is due to rising ambient temperature, the cooling water volume can be appropriately increased according to a certain proportion (such as increasing the cooling water volume by 10% - 15% for every 5℃ increase in ambient temperature). At the same time, the outlet water temperature can be observed. If the outlet water temperature still does not reach the target value, the cooling water volume can be further fine-tuned or other measures such as adjusting the fan speed can be taken.
Abnormal outlet water temperature: If the outlet water temperature is higher than the set target value, the cooling water volume can be gradually increased, and each increase should be 5% - 10%. Observe the outlet water temperature changes after a period of time (such as 10 - 15 minutes) until the outlet water temperature returns to the normal range; conversely, if the outlet water temperature is too low, the cooling water volume can be appropriately reduced, but care should be taken to avoid affecting the stability of the entire cooling system and the normal operation of the connected equipment due to too little water.
Adjustment strategy based on humidity changes:
High humidity: When the air humidity exceeds the set threshold (such as above 70%) and the outlet water temperature has an upward trend, the cooling water volume should be appropriately increased. The increase can be comprehensively judged based on the degree of humidity excess and the impact on the cooling effect. Generally, for every 10% increase in humidity, the cooling water volume should be increased by 5%-8%. At the same time, attention should be paid to whether auxiliary equipment such as fans need to be adjusted synchronously to enhance ventilation and promote heat exchange.
Low humidity: When the air humidity is low (such as below 30%), the cooling effect is good, and the outlet water temperature is lower than the target value, the cooling water volume can be appropriately reduced. The reduction ratio can be controlled at about 5%-10% to achieve energy saving and maintain stable operation of the system, but continuous monitoring should be carried out to prevent other problems caused by reduced water volume, such as scale accumulation in pipes.
Adjustment strategies based on wind speed and wind direction changes:
Influence of wind speed: When the wind speed is higher than the normal operating wind speed and the cooling effect is good, you can consider reducing the cooling water volume appropriately. The reduction amount is determined according to the wind speed and the actual cooling situation. For example, when the wind speed is 20% higher than usual and the outlet water temperature is stably lower than the target value, the cooling water volume can be reduced by 5% - 8%; on the contrary, when the wind speed is low, increase the cooling water volume or take other measures (such as adjusting the shutter angle of the cooling tower, etc.) to improve ventilation conditions and improve cooling efficiency.
Influence of wind direction: If it is monitored that unfavorable wind direction causes problems such as hot air reflux, which affects the cooling effect, you can first try to adjust the operation mode of the cooling tower (such as switching the fan direction, changing the shutter opening angle, etc.). If the effect is not good, increase the cooling water volume. The increase is determined by the degree of impact on the cooling effect, generally about 10% - 15%. At the same time, continue to pay attention to changes in wind direction and adjust the strategy in time.
IV. Continuous optimization and feedback adjustment
Effect evaluation:
After each adjustment of the cooling water volume, continuously observe the operating data of the cooling tower and the operating status of the equipment served, and evaluate whether the adjustment measures have achieved the expected optimal performance and energy-saving effect. For example, check whether the outlet water temperature is stable within the target range after adjustment, whether the heat exchange efficiency of the equipment has returned to normal, and whether the energy consumption of the entire cooling system has been reduced.
Feedback adjustment:
Based on the results of the effect evaluation, summarize the lessons learned, make feedback adjustments to the adjustment strategy, set thresholds, and data analysis methods, and continuously optimize the real-time adjustment of the cooling water volume plan to make it more in line with the actual operation situation, ensuring that the cooling tower can operate in the best performance and energy-saving state for a long time.
Through the above comprehensive and systematic methods, the real-time cooling water volume adjustment based on the operating data and environmental monitoring of the cooling tower can achieve the optimization of cooling tower performance and the improvement of energy-saving effects, and ensure that the entire cooling system can stably and efficiently serve related fields such as industrial production or building air conditioning.
Send Email
Skype
WhatsApp