Utilities & Environment
Automated control that holds approach temperature year-round.
Overview
A cooling tower quietly drifting off its approach temperature costs more than most plants realise, and manual logging rarely catches it in time. We automate control and monitoring for heat-rejection systems — and verify performance after handover.
In practice
A cooling tower rarely fails outright; it drifts. Approach temperature creeps up over a season, condenser pressure follows, and the chillers quietly consume more power for the same duty. We put fan speed under VFD control against measured approach rather than a fixed schedule, sequence multiple cells so they load evenly instead of one running against a stalled neighbour, and alarm on the drift itself so it surfaces as a maintenance job rather than an energy bill.
The mechanical protections belong in the same logic: vibration switches and gearbox oil-temperature interlocks wired to trip the fan and raise an event, not just cut power silently. On the water side we monitor conductivity and control blowdown against it, which holds cycles of concentration where they were designed to be — the single biggest lever on both make-up water consumption and scale on the fill.
Scope
Each item below is a package we build, install and support in-house — not a subcontracted line on a quote.
VFD-based fan and pump control responsive to measured load and approach temperature
SCADA integration for centralised monitoring across multiple towers
Vibration and condition-monitoring instrumentation with alarm thresholds
Water chemistry dosing control integrated with the monitoring system
Performance verification against approach and range after commissioning
Services applied
Sensor, transmitter and field-device selection, installation and loop checking for control systems that need real data.
DetailsSupervisory control, operator screens and alarm management built around how your operators actually work the line.
DetailsAnnual maintenance contracts and remote or on-site support for PLC, SCADA and DCS systems already in service.
DetailsProof points
SCADA & monitoring
Scope: Protocol conversion, SCADA integration and remote monitoring across mixed-vendor assets.
Result: Single dashboard replacing individual OEM portals, with alarm notification on faults.
Let's build
Send a scope, a drawing or just a problem statement. An engineer who knows this floor responds within one working day.
