Project Summary Sheet

Project Objective:  Cooling Tower Automation

Project Summary:

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The #2 Ladle Metallurgical Facility (LMF) utilizes three electrodes, which are lowered into the ladle and arced to bring the liquid steel up to a desired casting temperature.  Water is used to cool the ladle hood and associated equipment during operation.  An adjacent Cooling Tower facility provides treatment of the re-circulating cooling water.

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Provided electrical design and supervised installation of temperature, hardness, pH and flow meters and water control valves; initial calibration and verification of all sensors and valves; an Allen-Bradley PLC5 was used to completely automate Cooling Tower operation

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Normal operation of two out of the three main water pumps is cycled periodically to distribute usage

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Control of two main air-moving fans to cycle as required by water temperature; no fans for “cool” water, one fan for “warm” water, and two fans for “hot” water

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Monitoring of water flows, temperature differentials, water hardness and pH (blow-down and make-ups as required), water clarity (dispensing of detergent compound as required), and well water level (make-up as required)

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The operator interface was implemented with Allen-Bradley ControlView

Economic Summary:

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Load-dependent cycling of water pumps and air-moving fans maximizes equipment efficiency, helps minimize maintenance, and prolongs equipment life thru reduced wear and tear

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Maximized long-term cooling efficiencies by preventing pipe restrictions from algae and calcium deposits thru detergent additions and pH control (also reduces corrosion)

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Reduced water costs from minimized blow-down frequency thru detergent additions to maintain water clarity

671 Columbia Rd., Suite 8, P.O. Box 450858, Westlake, OH 44145-0858  ·  (440) 899-1676  Fax (440) 899-9267

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