New Cooling Tower Monitoring Solution added to Essential Asset Monitoring Capabilities

EMERSON NEWS RELEASE: Emerson’s new Cooling Tower Monitoring Solution ensures cooling water availability, maintains water quality and reduces chemical costs for process plants 
Easy to implement monitoring solution mitigates slowdowns and shutdowns due to cooling water tower issues

AUSTIN, TEXAS (October 21, 2013) — Emerson Process Management has introduced an integrated Cooling Tower Monitoring solution as the latest addition to its Essential Asset Monitoring capabilities.

The new Cooling Tower solution monitors the water cycle of the cooling tower that services process plants, helping operators ensure that makeup water and chemical costs are optimized while minimizing scaling and fouling of cooling water exchangers facility-wide. The solution provides a complete set of pre-engineered applications for 24/7 online monitoring and analysis of the cooling tower and its related equipment health. It uses wireless instrument networks with existing wired instruments to provide affordable, easy-to-implement, automatic monitoring.

Cooling water quality and availability is critical for maintaining production at most operating facilities. Process plants and refineries circulate thousands of gallons of water through cooling water systems. Plants in hot climates are particularly susceptible to cooling-limited conditions during summer months. Conversely, plants in cold climates are concerned with equipment freezing and damaging cooling tower internals. Poor water quality can lead to rapid fouling in the entire heat exchanger network, reducing cooling effectiveness, potentially limiting production, and requiring additional maintenance services and outages for cleaning.

A problem with a cooling water pump or a fan failure forces operators to react to an immediate loss of cooling capacity. Even if a plant shutdown is not required, interruption in cooling water supply can cause pressure relief valve releases and require temporary reductions in throughput, resulting in underutilization of the plant assets.

Since chemicals, additives and fresh water treatment are some of the largest variable costs for cooling tower operation, optimizing purge and makeup rates is important.  Proper control of water cycles and chemicals to maintain water quality requires on-line measurement of water quality. Many plants operate based on daily or even weekly analysis of their cooling water. On-line monitoring of cooling water quality can result in lower makeup water and chemical costs, as well as elimination of fouling events in the exchanger circuit.

“To confront common challenges of operating cooling towers, Emerson has developed a new essential asset monitoring module that analyzes process and equipment data to determine an overall cooling tower health indicator and generate alerts when something abnormal is detected,” commented Pete Sharpe, director of applications development for Emerson. “Cooling tower equipment is located in wet, slippery environments, so it is not the ideal location to send maintenance technicians out with a handheld to take manual measurements.  By installing wireless monitoring devices on their cooling tower fans, customers can eliminate manual rounds — increasing worker safety, saving time, and freeing technicians for higher level tasks. Further, continuous monitoring delivers alerts that enable planned maintenance which is quicker and more cost effective than reaction to failures.”  

“All told,” said Sharpe,  “we estimate that on-line monitoring and analysis of a large 350,000 gpm cooling water system can add up to $450,000 in savings annually due to reductions in lost production, lower energy bills, and a reduced chemical and water usage.”

The new Cooling Tower Monitoring release adds to the growing family of Essential Asset Monitoring solutions which include monitoring solutions for pumps, blowers, compressors, and heat exchangers, with other asset types under development. The Essential Asset Monitoring solution from Emerson includes the software and any new devices required and commissioning services.

For more information, go to

About Emerson Process Management

Emerson Process Management (, an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb™, Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel™, Ovation™, Bettis™ and AMS Suite.

About Emerson

Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial, and consumer markets around the world.  The company is comprised of five business segments: Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions.  Sales in fiscal 2012 were $24.4 billion.  For more information, visit

This entry was posted in Cooling Tower, Emerson, Emerson Process Management, Essential Asset Monitoring and tagged , , , . Bookmark the permalink.

Comments are closed.