GE Oil & Gas

Induced Draft Cooling Tower and

Air-Cooled Heat Exchanger Monitoring
Application Guide
Table of Contents
1 Description of “Wet” Cooling Tower Fans............................................2 7 Cooling Fan In-Depth Analysis............................................................ 15

2 Air-Cooled Heat Exchanger (ACHE) ......................................................2 7.1 Cooling tower description and operation .................................................15

3 Induced Draft Fan Monitoring Challenges...........................................3 Types of Towers.......................................................................................................16

4 Failure Modes – What We Can Detect...................................................4 Natural Draft Towers............................................................................................16

4.1 Fan.....................................................................................................................................4 Mechanical Draft Towers....................................................................................16

4.2 Cooling Tower Gearbox ..........................................................................................4 7.2 The cooling tower mechanical system.........................................................16

4.3 Belts and bushings....................................................................................................4 7.3 Problems associated with cooling tower mechanical systems...... 17

4.4 Motor................................................................................................................................5 Fan assembly related problems...................................................................... 17

5 Selecting the Proper Transducer and Monitor Solution....................5 Non-mechanical cooling tower problems.................................................. 17

5.1 Transducer selection................................................................................................5 Fin fan operation and description.................................................................. 17

5.2 Monitor selection ......................................................................................................6 7.4 Observations.............................................................................................................18

Protection System.....................................................................................................9 Changing Attitudes: ..............................................................................................18

Management System Only....................................................................................9

6 Appendix and supporting information.............................................. 10

6.1 Monitoring solutions.............................................................................................10

Protection ..................................................................................................................10

6.2 Sensors.........................................................................................................................12

190501 Velomitor CT:...........................................................................................12

200350 and 200355 Accelerometers...........................................................13

200155 Accelerometers......................................................................................13

AM1-100-T2 Accelerometer (Commtest)....................................................14

AM3100T2-Z2 (Commtest).................................................................................14

AS3100S2-Z2 (Commtest)..................................................................................14

application note
application note
Abstract: Industrial fans provide important cooling to a variety
of processes throughout the power generation and oil and gas
1 Description of “Wet”
industries. Production is often reduced or curtailed when fans fail Cooling Tower Fans
and cooling capacity is reduced.
Two very common types of fan categories are the mechanical
induced-draft, evaporative type (commonly referred to as cooling
tower fans) and the air-cooled heat exchanger type (ACHE or
fin fans*). Both asset types present unique challenges when
selecting the proper solution for fan assembly monitoring.
Note: Another cooling tower variation is the forced draft cooling
tower where the fan is located at the air inlet rather than the
air outlet. These cooling towers are not covered in this guide.
The purpose of this document is to help Sales Managers/Channel
Figure 1. Typical Cooling Tower
partners apply the proper solutions to their customers’ unique
From Cooling Tower Manufacturers in Mumbai, www.gtpl.co.in
fan protection and condition monitoring problems for GE’s
Bently Nevada product line. Cooling towers are heat removal devices used to transfer
process waste heat to the atmosphere. Cooling towers
Note: Machinery protection is implemented when vibration
evaporate water to remove heat from a process or machine.
(or other) instruments are installed permanently onto a machine
and connected to a dedicated monitoring and protection system. Large amounts of air must be moved through a cascade of
The protection system has alarm setpoints, which are set by the water to provide adequate evaporation and the desired cooling.
machinery OEM or the end user to automatically raise an alarm The prime mover of air is the cooling tower axial fan assembly,
when the predetermined alarm level is reached. The system has which is mounted on the upper deck of a cooling tower.
alarm relays for alert and danger conditions that can initiate The fan is typically seven or more blades with a radius of
an automatic shutdown or trip of the machine; alternatively, about 5 to 30 feet. The fan is situated horizontally inside a
instructions to shut down the machine may be acted upon cylinder-like fan stack (or fan housing) on top of a right-angle,
by an operator when an alarm occurs. Machinery protection speed-reducing gearbox.
is necessary and valuable since it may prevent or minimize
machine damage and consequential losses in the event that A long drive shaft or propeller shaft passes through to the
a sudden machinery or process malfunction occurs. outside of the fan stack and connects the gearbox to an electric
motor. In some cases, the motor and fan assembly are both
Safety: Cooling towers are dangerous places. Fans are on top of inside the fan stack.
the fan deck, which requires climbing stairs. Sensors are mounted
inside the fan stack, and safe access to the gearbox can be difficult. The motor turns the shaft, and torque is transmitted through
the speed-reducing right angle gearbox, turning the fan at speeds
ACHEs often are installed well above grade level and require of 60 to 300 RPM. The fan produces a strong upward draft that
climbing ladders or steps to access the sensor locations. exits at the top of the fan stack, rejecting heat and water vapor
into the atmosphere.

2 Air-Cooled Heat Exchanger (ACHE)

Figure 2. Typical ACHE Installation

From air exchangers | companies www.europages.co.uk
Unlike the cooling tower, the ACHE is a “dry” fan that simply
moves air over tubes that contain hot process fluid. Heat is
removed from the process fluid as the air passes over the tube
bundle. The cooling is often aided by fins that are attached to
the tubes. The fins increase the cooling surface area and are the

2
 application note
reason some ACHEs are called “fin fans.” An ACHE operates on Environment: With induced draft cooling tower fans, most of the
the same principal as that of an automobile radiator. monitoring focus is on the gearbox, and the gearbox is located
within the fan stack. The warm, moist environment inside the fan
stack is very turbulent. Algae, bio fouling and corrosion are the
biggest problems to overcome when installing vibration sensors
in a cooling tower. Protecting the sensor connector and cable is
very difficult because even the best connector/cable system will
succumb to the environment over time. An integral connector/cable
Figure 3. Heat Exchanger Finned Tube is the best choice for sensor longevity, but not the easiest to install
Heap Dawson, www.heapdawson.co.uk or maintain.
Fans are mounted below (forced draft) or above (induced draft) When instrumenting an induced draft ACHE, the sensor could be
the heat exchanger, as shown below. exposed to a temperature that exceeds the limits of our sensors,
so it is important to know the temperature limit and choose the
appropriate sensor.
Rotational speed: For cooling towers, sensors must be able to
detect high-frequency gear and bearing faults and at the same time
detect very low-speed fan-related faults. ACHE speeds are usually
well within our sensor frequency range.
Location: Where to locate the monitor system is always a concern.
Mounting it up on the fan deck is easiest and most cost-effective
from a wiring point of view, but fan decks present a safety hazard to
people who need access to the monitoring system and expose the
monitoring system to a corrosive, wet environment. Mounting the
monitors at a central location at grade level is the most convenient,
but also is the most expensive, considering the electrical
implementation requirements.
Note: Sensor cable lengths of more than 100 feet should be
reviewed carefully against the transducer data sheet to assure the
signal is not attenuated, causing a loss of critical sensor signal.

Figure 4. Example of Induced Draft and Forced Draft Fin Fan

FinFan Technical Info www.hudsonproducts.com
Generally speaking, ACHE fans are usually smaller and operate
at a higher speed than cooling tower fans. The fan is powered
by an electric motor and is often belt-driven, with some using a
right angle gear drive. ACHEs often are mounted in “banks” where
multiple fans are arranged in long rows. ACHEs often are mounted
well above grade so that the hot air is ejected high enough to not
cause problems with people or surrounding assets.

3 Induced Draft Fan

Monitoring Challenges

Figure 6. 1900 installation

Figure 5. Algae in Cooling Tower Environment

www.environmentalleverage.com

3
application note
4 Failure Modes – What We Can Detect The central component of a cooling tower fan is the gearbox.
This is often a high-maintenance source due to aerodynamic
loading from the fan, excessive loading on the gear teeth, and
improper alignment of the gearbox to the motor. Many gearbox
failure modes are secondary in nature. For instance, the failure
of an intermediate shaft lower bearing allows the gearing to
operate off parallel axis, and hence the gear teeth fail due
to poor distribution of load. The gearbox is always located
within the cooling water stream requiring special consideration
for mounting a vibration sensor. Also, the environment is usually
caustic due to chemicals added to control the pH level of the
cooling water.2
A vibration sensor must be able to measure the expected gear
mesh frequency, blade passage, and bearing defect frequencies.
Other frequencies of interest include fan balance and motor
alignment. Gear and bearing defect frequencies tend to be the
highest frequencies, while the fan balance frequencies are the
Figure 7. Typical Cooling Tower Gearbox and Fan lowest to be monitored. The other frequencies are found
Cooling Tower Fans, Cooling Tower Fan Parts | amertechtower.com scattered between these extremes.
extraordinaryvitality.com Monitoring of the gearbox can be
accomplished by installing
accelerometers at both the input
4.1 Fan and output shaft in a horizontal
orientation. The output signals
The most common industrial cooling fan failure modes
from these sensors can be routed
typically involve gearboxes or fan blades and are catastrophic
to a protection monitor for the
in nature. In many cases, this type of failure leaves the gearbox
purpose of shutdown due to high
and/or fan blades lying in the cooling water pond at the bottom
vibration or terminated at some
of the tower or above a heat exchanger.1
convenient location for interfacing
These failure modes are detected using a standard piezoelectric with a portable vibration data
accelerometer or a Velomitor* sensor. These sensors can be collector or scanning system.
chosen to encompass the entire frequency range of expected
Example of gear frequency calculation:
defects and used to either protect or monitor for condition
based maintenance. • The highpass corner frequency of the gearbox seismic
transducer should be below the running speed of the fan.
For example, if the fun turns at 120 RPM, the highpass
4.2 Cooling Tower Gearbox corner of the accelerometer would need to be less than 2 Hz.
This is also required to detect problems with the fan.
• The lowpass corner frequency should be higher than
3X the highest mesh frequency, but monitoring at a
minimum of 2.25 X GMF will give ample indication of
an early gearbox issue. For example, a sample cooling
tower gearbox from a plant in Texas has a motor speed
of 1,780 RPM and 16 teeth on the pinion. This means that
the mesh frequency is 474.7 Hz and that the 3X mesh
frequency is 1,424 Hz.

4.3 Belts and bushings

Belt-related failure modes are somewhat common in industrial
fin fan applications. In general, belts used with these machines
can be categorized into two different types: standard V-belts and
timing or gear belts. V-belt frequencies are always below the RPM
of either the motor or the driven machine. When they are worn,
Figure 8. Typical Right-Angle Cooling Tower Gearbox
Paharpur Cooling Towers Ltd. www.paharpur.com loose or mismatched, they normally cause three to four multiples or
harmonics of belt rotation frequency (see inset).

1 Reliabilityweb.com 2 Reliabilityweb.com

4
 application note
are capable of taking advantage of the Enveloping signal
Belt Frequency =
processing feature provided by the several of the GE and
3.14 x Pulley Speed x Pulley Diameter/Belt Length
Commtest monitor solutions.
In this scenario, two times belt frequency is often the dominant
peak. Amplitudes are normally unsteady and sometimes will pulse
with either the driver or driven RPM. In regards to timing or gear
belts, wear or pulley misalignment is most commonly indicated by
high amplitudes at the timing belt frequency (see inset).

Timing Belt Frequency =

# of Sprocket Teeth x Shaft RPM

Another defect frequency is misalignment of pulleys and pulley

eccentricity, which typically results in excessive run speed vibration The Velomitor CT is a velocity
in the axial direction and the radial direction respectively. transducer designed for cooling
tower applications. It provides a
good signal at the lower end of the
frequency response curve and is the
4.4 Motor best choice for protecting the fan
Motor vibration frequencies of interest include motor unbalance, from large imbalance or blade
rotor bar defects, output shaft alignment, and bearing defect separation problems.
frequencies. A complimentary continuous/scanning monitoring
The Velomitor CT signal is not
approach typically should include one accelerometer per bearing
compatible with acceleration
location. Mounting orientation for the accelerometers should
enveloping.
be horizontal at the bearing since this is usually the axis that is
most compliant. As the motor speed is usually 1800/1500 RPM, Select the cable and connector type that can withstand the
economical standard accelerometers can be used. harsh CT environment. The CB2W100 cable assembly is an
excellent choice for most two-pin MIL accelerometers used
in cooling tower monitoring and protection. The Velomitor CT
is designed to interface with conduit for added protection of
the connector and cable. Commtest provides some excellent
accelerometer choices.

Figure 9. External Cooling Tower Motor

Cooling Fan Motor images pix-hd.com

5 Selecting the Proper Transducer

and Monitor Solution

5.1 Transducer selection

GE has a wide range of accelerometers that can detect the
major gearbox and fan failure modes.
Figure 10. Typical 190501 Velomitor CT installation
All of the accelerometers in this document have a “low end”
frequency response of between 12 and 90 RPM, allowing them See the transducer detailed description in the appendix for
to detect 1X amplitudes in most applications. All accelerometers more information.

5
application note
Sensor Chart
  190501 Vel CT 200350 200355 200155 AM1-100-T2 AM3100T2-Z2 AS3100S2-Z2
Sensitivity 100mv/in/sec 100mv/G 100mv/G 100mv/G 100mv/G 100mv/G 100mv/G
Accuracy ±5% ±20% ±5% ±12% ±5% ±5% ±10%
Freq. 1.5Hz-1.0kHz 0.5Hz - 10kHz 0.2Hz - 10kHz 1.5Hz - 10kHz 0.4Hz - 13kHz 0.4Hz - 14kHz 0.7Hz - 10kHz
Response
(3db)
Dynamic ±2.5 in/s, peak ±50g, peak ±50g, peak ±20g, peak ±80g, peak ±80g, peak ±80g, peak
Range
Exit Top Top Top Top Top Top Right
Pricing $$$ $$ $$$$ $$ $ $ $$

Note: Despite the datasheet range specified, practically it is very difficult to use an accelerometer to measure vibration at fan speed. For
example: If a fan is running at 120 RPM (2 Hz) and moving 2mm (80 mil) pk-pk, an accelerometer with a scale factor of 100mV/g will produce
a signal of 1.6mV. A Velomitor CT with a scale factor of 500 mv/in/sec will output a 250 mv signal. Practical experience has shown that the
noise floor for permanently installed sensors can be as high as 5mV so it is very difficult to determine the low speed shaft motion with an
accelerometer. It is preferable to monitor the output shaft with a Velomitor CT and the input shaft with an accelerometer rather than using
an accelerometer on both shafts. An accelerometer, however, is necessary for acceleration enveloping, which is useful in detecting certain
gear problems. Select a sensor or combination of sensors that have the necessary frequency response to detect the faults of interest.
Accelerometer Mounting Caution: Careful consideration must be given to the mounting arrangement. A poorly mounted sensor can
have a much lower mounted resonance compared to the stated value in the datasheet.
Keyphasor*: If the cooling tower is especially large or critical (and this is rare) or if the unit is a variable speed, a Keyphasor should be
installed to capture the fan speed. This makes it easier to detect and differentiate gear faults and bearing faults, especially on gearboxes
with an intermediate shaft.

5.2 Monitor selection Cost is often a factor in the monitor selection

process. At a minimum, customers will want
The criticality ranking of the fan is often the deciding factor when a cost-effective solution to monitor the health
considering monitoring solutions. of the gearbox and have some indication of
If the customer needs machinery protection, the best choice is the significant events (such as blade/hub
1900/65A with Velomitor CT sensor or a combination of Velomitor separation) requiring immediate attention. In
CT & accelerometers. some cases, protection is required, for instance
when upgrading from vibration switches to
Fan criticality will determine the best choice: machinery protection, more sophisticated monitoring systems.
machine condition monitoring, or simply doing nothing.
Note: The recently introduced 2300 Series vibration monitor
provides many of the features of the 1900/65A monitor and may
be a consideration for a CT or fin fan application. The 2300 Series
does not currently support Velomitor sensors, proximity sensors
or temperature. However, these enhancements are planned.
Check with the FAE or Product Line Manager to determine the
suitability of the 2300 Series in a low speed fan application.

http://www.maintenancephoenix.com/2013/10/02/
pf-curve-101-keeping-it-simple/
Criticality ranking is the responsibility of the user, but GE can help
by providing risk assessment services and assistance if needed. 2300 Series vibration monitor

6
 application note
Below is a monitor/transducer compatibility and criticality chart to help determine the most appropriate solution.

Monitor/Transducer Compatibility Chart

Essential
1900/65 2300 DSM Vb Online Insight.mesh Scout
190501 X Not supported   X   X
Velomitor CT
200350 X X X X   X

Sensors 200355 X X X X   X
AM1-100-T2 X X X X   X
AM3100T2-Z2 X X X X   X
AS3100S2-Z2 X X X X   X
Ranger     X    
200155   X     X  
High X X        
(Protection)
Criticality H (Monitoring)   X X   X
Medium   X X X X
Low     X X X

Monitor Solutions Chart

Essential
DSM (direct SCOUT Insight.mesh*
1900/65a 2300 input card) vbOnline* Ranger 100/140* (EI.Mesh)
Protection X X          
Cond Mon X X X X X X X
Cooling Tower X X X X X X
App
ACHE App X X X X X X X
Enveloping X X X X X X X
Sensors A,V A A,V A,V Ranger is a A,V A
sensor
Band Pass X X X X X X X
Input Channels 4 2 32 16 2/wireless 2/4 4/wSIM
sensor
Relays 4 2 0 2 0 0 0
Modbus X Q1 2016 X Only as input      
Software None System 1* System 1* Ascent Ascent Ascent System 1
Interface

7
application note
Monitor Solution Strengths and Limitations
Solution Strength Limitations
• Machine protection Difficult to interface with GE’s System 1*
• Vibration and temperature machinery management software (S1)
1900/65A • Enveloping
• Local display
• Modbus communications
• Monitoring and protection • No Velomitor input
• Two acceleration inputs • No proximity input
2300 Series vibration monitor
• Synchronized sampling • No temperature input
• One Keyphasor/speed channel (these are planned enhancements)
• High channel density • No protection
• Small footprint • Requires Ascent to view data
• Easy to configure
vbOnline/Ranger
• Enveloping
• Accepts wide variety of sensors
• Low cost per channel
• Wireless • No protection
• Acceleration and temperature • No velocity below 600 CPM
Essential Insight.mesh • Long distance • Not qualified for installation within
• Small footprint wet cooling tower environment
• Enveloping • Requires S1 to view data
• High channel density • No protection
• Enveloping • High cost (if S1 needed)
DSM
• Low cost (Modbus)
• Modbus communications
Condition monitoring and diagnostics • Walk around
SCOUT
• No access to CT gearbox

General Decision Tree

8
 application note
Protection System
Example Case 1: 1900/65A monitor
Item No Qty Model No Comments
1 1 1900/65A monitor General purpose vibration monitor
2 4 200350 Accelerometer
2 on Gearbox, 2 on Motor
(Typically 1 accelerometer on Motor DE side)
3 4 CB2W100-xx Accelerometer cable, xx (= length option)
4-1 1 168628 Stainless steel NEMA 4X weatherproof door for panel-mount
display assembly
4-2 1 168944 Fiberglass NEMA 4X/IP66 weatherproof housing with window in door

Management System Only

Example Case 2: Vb Online
Item No Qty Model No Comments
1 1 KTOC0534 Vb Online 16 device (16Ch) - Complete Kit. 16 channels active with
Level 3 Software
2 4 AM1-100-T2 Accelerometer
3 4 CB2W100-xx Accelerometer cable, xx (= length option)

Example Case 3: Dynamic scanning module (DSM) + seismic direct input card option
Item No Qty Model No Comments
1 1 149744-aa-bb-05-dd-ee-ff-gg-hh Dynamic scanning module + 1 seismic direct input card
2 4 200350 Accelerometer
2 on G/B, 2 on Motor
(Typically 1 accelerometer on Motor DE side)
3 4 CB2W100-xx Accelerometer cable, xx (= length option)
4-1 1 168628 Stainless steel NEMA 4X weatherproof door for panel-mount
display assembly
4-2 1 168944 Fiberglass NEMA 4X/IP66 weatherproof housing with window in door
5 1 3010-56 DSM Modbus exporter software
6 1 172555 Modbus serial-to-Ethernet bridge

9
application note
6 Appendix and supporting information The dedicated buffer output can provide the signal for each
transducer input.
A Modbus Gateway option allows the monitor to provide static
6.1 Monitoring solutions variables, statuses, event list, and time and date information
directly to any Modbus client, including distributed control
Protection systems (DCSs), supervisory control and data acquisition
The 1900/65A General Purpose Equipment Monitor is designed (SCADA) systems, programmable logic controllers (PLCs).
to continuously monitor and protect equipment that is used in a Monitoring solutions
variety of applications and industries. The monitor’s low cost makes
it an ideal solution for general purpose machines and processes SCOUT is well suited for use in monitoring the condition or
that can benefit from continuous monitoring and protection. asset health of industrial cooling fans. It is categorized as
a PVDC (portable vibration data collector), which lends itself
The 1900/65A monitor well to the location where these fans typically are installed.
provides four transducer From a convenience standpoint, these fans often are located in
inputs and four temperature areas that are somewhat difficult to reach, requiring traversing
inputs. Software can stairwells and ladders.
configure each transducer
input to support 2- and Due its lightweight and portable form, SCOUT easily can be
3-wire accelerometers, worn as an accessory for interfacing with permanently mounted
velocity sensors or proximity sensors that are attached to the motor, gearbox or fan.
sensors. Each temperature BNC connectors typically
input supports Type E, J, K, are routed to the exterior
and T thermocouples, and of the cooling tower or
2- or 3-wire RTDs. ACHE (air cooled heat
exchanger) applications
and easily can be
connected to a SCOUT
instrument for data
collection.
This data collection most commonly is performed on a monthly
basis but can be more or less frequent, based on the criticality
ranking associated with the machine and available resources.
Due to the wide range of frequency response capable with
SCOUT, and the ability to receive this data into Ascent vibration
analysis software, all common fault modes associated with
these equipment types can be measured, identified, and
trended. SCOUT comes in two varieties, a two-channel device
(SCOUT100) and a four-channel device (SCOUT140). They are
essentially the same device, with the main differentiating
factors being channel density and additional analysis
capabilities for the SCOUT140.

vbOnline can be viewed in a very similar way to SCOUT. The

main difference is that vbOnline is a permanently installed
scanning solution that offers the opportunity for more
frequency data collection.
This product is best used with machines ranked as mid-criticality but
not requiring protection. As with SCOUT, vbOnline interfaces
with Ascent for data housing, diagnostics and analytical approaches.
This is facilitated by an Ethernet TCP/IP connection to a plant
LAN that allows two-way communications between vbOnline
The 1900/65A monitor provides six relay outputs, four 4-20 mA and the Ascent database.
recorder outputs, and a dedicated buffered output. The user
Data collection is performed using the same piezoelectric
can use the 1900 Configuration software to configure the relay
accelerometers that typically are mounted at the motor,
contacts to open or close according to the OK, Alert and Danger
gearbox, or fan and can be scheduled based on condition-based
statuses of any channel or combination of channels, and to provide
parameters using the Ascent configuration portal.
data from any variable from any channel on any recorder output.

10
 application note
Once configured, these schedules are maintained by the Ascent The Essential Insight.mesh wireless condition monitoring
Online Manager service that can be housed on the Ascent database platform is a wireless data acquisition system that is fully
server. Data collection will be automated without the need for integrated with System 1 software.
Ascent interaction and will continue until the service is either
stopped or altered.
This data will be pushed into
the Ascent database for
viewing with the Ascent
software. vbOnline comes
standard with 16 input
channels and can interface
with any sensor providing
an mv/EU signal. In addition,
this monitor also can accept
4-20 ma signals and Modbus
communications for entry
into Ascent. A typical system requires a manager gateway, wSIM devices –
wireless sensor interface modules – and repeaters, which
It also has two onboard tachometers or Keyphasor inputs for phase create a robust, auto forming mesh network.
information or condition-based data collection and two relays that
can be configured to annunciate an event of some type based on Each wSIM device has four channels, each of which can be
alarm conditions within Ascent. configured individually to support vibration and temperature
measurements.
Ranger (for use in USA only) The Essential Insight.mesh wSIM devices support GE’s Bently
is a wireless solution from our Nevada 200155 accelerometers, as well as our 200125 K-Type and
Commtest portfolio that fits standard J-, T- and E-Type thermocouple temperature sensors.
well with the monitoring
scheme required for industrial
cooling fans.
It is a scalable wireless mesh
system that uses the ZigBee
communication protocol and
offers a permanently mounted
condition monitoring approach
that is both affordable and
dependable. Ranger is composed
of three major pieces that work
together to form a monitoring
platform that interfaces with
Ascent.
The first piece of the product is the Ranger wireless sensor that can
measure vibration in two different axes along with temperature.
Frequency response is acceptable for this application (3 Hz to 10
The Essential Insight.mesh platform is compatible with the
kHz) in the vertical direction, and the sensor is pre-manufactured
ISA100.11a protocol with System 1 integration. The ISA100 protocol
with a threaded connection (1/4-28) for permanent installation.
is an open, industrial standard providing for interoperability with
It also has the ability to perform demodulation (2 kHz to 10 kHz
any other ISA100 wireless device.
bandwidth) onboard the sensor and can Wake-On-High vibration
for data collection. The Essential Insight.mesh wSIM and repeater devices have flexible
power options that include both a replaceable, integrated lithium
The next piece is the Ranger wireless booster, which is used to
thionyl chloride battery module and external
help expand the range of the wireless mesh network and aids in
power modules with battery backup.
transmitting data back to the plant LAN via a base station.
The external power module can eliminate the
The last piece is the Ranger base station, which accepts signals
cost of replacement batteries and allow for
transmitted from either the wireless sensors or boosters. This
the selection of more frequent data collection
base station has dual communication capabilities in the way of
to meet a broader range of applications.
the IEEE 802.11 wireless protocol or wired Ethernet TCP/IP. From
The power options provide the flexibility
either of these connections, data is then passed back to Ascent
to implement the deployment that best
for storage, trending, analysis, and reporting.
fits the application.

11
application note
The 149744 Trendmaster dynamic scanning module (DSM)
is a compact rack-based data acquisition system that is fully
6.2 Sensors
integrated with System 1 software. The DSM rack has five card CAUTION: Any sensor that is installed within the wet
slots. The first slot is dedicated for communications and will environment of a cooling tower MUST have adequate
accept either the copper or fiber Ethernet card. The other connector protection or an integral cable. If the sensor
four slots are general-purpose card slots that can accept connector is exposed to the humid and hot environment,
any combination of the available DSM input cards. the sensor lifetime may be greatly reduced due to corrosion
of the connector.
The DSM supports Seismic Direct Input Card 164746-01,
which connects directly to sensors. Direct input cards support 190501 Velomitor CT:
up to eight channels and provide very rapid scanning. All input
The Velomitor CT velocity transducer is a low-frequency version of
card types offer high-resolution sampling with onboard
our standard Velomitor piezo-velocity sensor. Its design specifically
real-time processing.
measures casing vibration velocity on cooling tower and air-cooled
heat-exchanger fan assemblies that operate at or above 90 rpm
(typically 100 to 300 rpm). The Velomitor CT transducer can measure
vibration amplitudes at these frequencies as well as the vibration
frequencies generated by the fan motor and speed reducer.

Frequency Response:
1.5 Hz to 1.0 kHz (90 to 60,000 cpm) ±3.0 dB

Onboard processing is the key to the powerful and efficient

features available with the DSM platform. Because each
input card can process data locally, the DSM can return
post-processed variables to the host computer and reduce
the required network bandwidth.
If the host computer requires raw data, the DSM also can
return waveforms and spectrums.
The introduction of a Modbus digital interface now permits
DSMs to communicate directly with process control and
automation systems without the need for additional hardware.
This capability provides a low-cost entry-level alternative to
System 1 software that uses the basic trending and alarming
functionality that is integral to existing process control systems.
All DSMs now include Modbus over TCP/IP capability and require
only the DSM Modbus Exporter software to configure all the
DSM inputs and define the Modbus interface.

12
 application note
200350 and 200355 Accelerometers 200155 Accelerometers
The 200350 and 200355 accelerometers are general purpose, The 200155 low-frequency accelerometer is designed
case-mounted seismic transducers designed for use with for use only with Essential Insight.mesh wireless condition
DSM Seismic Direct Input Card 164746-01. monitoring and should be used only for low speed applications
such as heat exchanger fin fans.
The 200350 and 200355 accelerometers are contained
within a hermetically sealed, stainless steel case. The design The 200155’s broad frequency response requires a longer
provides an extremely rugged transducer, well suited for settling time for measurements and should therefore not be
harsh industrial environments. Each transducer’s top-mounted, used unless low frequency response is specifically required
two-pin connector (MIL-C-5015) allows for easy installation by the application. The transducer features extremely robust
and removal of the interconnecting signal cable. A 1/4-28 construction, using a hermetically sealed, stainless steel case.
threaded hole on the bottom of the casing accommodates
multiple mounting options. Frequency Response:
1.5 Hz to 10,000 Hz (90 to 600,000 cpm) ±3.0 dB
The 200350 and 200355 accelerometers contain a piezoelectric
sensing device, which generates charge when subjected to
vibration. This charge then is converted electronically to
a differential voltage signal, which is proportional to the
acceleration that is parallel to the sensitive axis of
the transducer.

Frequency Response:
200350: 0.5 Hz to 10,000 Hz (30 to 600,000 cpm) ±3.0 dB
200355: 0.2 Hz to 10,000 Hz (12 to 600,000 cpm) ±3.0 dB

200350/355

13
application note
AM1-100-T2 Accelerometer (Commtest) AS3100S2-Z2 (Commtest)
General purpose accelerometer. 100 mV/g, side exit, +/-5%,
Frequency response:
80 g peak acceleration range, 1/4-28 mounting thread.
0.4 Hz to 13,000 Hz (24 to 780,000 cpm) ±3.0 dB
Large – 145 g, C1D2-rated.

Frequency response:
0.7 Hz to 10,000 Hz (42 to 600,000 cpm) ±3.0 dB

AM3100T2-Z2 (Commtest)
General purpose accelerometer. 100 mV/g, top exit, +/-5%,
80 g peak acceleration range, 1/4-28 mounting thread.
Large – 142 g, C1D2-rated.

Frequency Response:
0.4 Hz to 14,000 Hz (24 to 840,000 cpm) ±3.0 dB

14
 application note
7 Cooling Fan In-Depth Analysis Unfortunately for fan users, the effectiveness of the vibration
switch is a hit-or-miss proposition at best. Users have shared
Heat dissipation is one of the most common processes in accounts of fan failures where the switch acted too late, or not at
the industrial plant. Cooling towers and air-cooled heat all, during a fan failure. What users want is a reliable monitoring
exchangers (fin fans) are the two most common methods for system that can provide not only shutdown capability, but a
removing waste heat. pre-shutdown warning of increasing vibration amplitudes, access
Cooling tower and fin fan use is on the rise due to economic to the vibration signal for analysis, remote reset capability, a way
and environmental reasons related to heat removal. In a to verify alarm set points, and a way to periodically verify if the
chemical plant or refinery, for instance, cooling towers provide monitor is operating properly.
the least expensive way of providing large amounts of chilled Safety is also a concern. In order to manage a fan mechanical
water to a processes’ heat exchange system. problem, operators need as much warning as possible to safely
Fin fans are best suited for applications where precise control take a fan out of service for repairs. Effective shutdown capability
of process liquids is required, such as in a styrene unit where is also a must for failures that happen instantaneously.
the process liquid is fed directly into the heat exchanger. The industry needs a reliable fan monitoring system that can
Power generation facilities are using cooling towers in their address the unique needs of cooling towers and fin fans. GE has
efforts to comply with environmental regulations. Plants are the experience, knowledge and products to provide a quality fan
no longer allowed free use of lakes, rivers, or other natural bodies monitoring and protection system.
of water for cooling water. If water from a natural source is used,
it must be cooled before it is discharged from the plant.
Cooling towers are being installed to either comply with
7.1 Cooling tower description
thermal discharge limits set by the EPA, or as part of a and operation
completely self-contained closed loop cooling water system Cooling towers and fin fans are used throughout the refining,
that eliminates discharge. In areas where water is not available petrochemical and power generation industries as a means
for evaporative cooling, fin fans can be used. of dissipating unwanted heat to the atmosphere. Even though
Some geothermal power generation facilities use fin fan their objectives are the same, cooling towers and fin fans differ
cooling in this manner. significantly in design and usage.
Because cooling towers and fin fans often are located in A cooling tower is a device for reducing the temperature of water
remote areas of the plant, they have traditionally not enjoyed by bringing it in contact with air. Most of the heat exchange in a
the maintenance attention compared to other machines that cooling tower happens through the evaporative process when
are located within process unit. hot water is passed over cool air through a medium called “fill.”
As water falls through the fill, air is blown across it by a fan.
However, plants can no longer afford to ignore these machines.
As the water evaporates, an exchange of heat takes place, the
They are simply too important to the process and too expensive
temperature of the water is reduced, and heat is rejected to
to operate in a breakdown maintenance mode. The trend now
the atmosphere.
is to apply the same modern maintenance techniques and
tools to the heat removal systems that are being used on the The critical need for energy efficient cooling together with water
process machinery. conservation has increased the popularity of cooling towers.
This trend is creating demand for better products and services The cooling tower is a large, framed structure with wood being
for cooling tower and fin fan maintenance. the most common building material. Man-made materials such
as steel, fiberglass, and concrete are becoming increasingly
It also is changing the way fans are monitored. Cooling tower
popular because the price of wood is increasing every year, and
and fin fan users are demanding better machinery monitoring
because the chemicals used to preserve the wood are being
capability for their fan mechanical systems. Two areas of concern
scrutinized by the EPA.
for plant maintenance and operations are availability of the
cooling system and safety. The fan deck is at the top of the tower and consists of the fan
mechanical assembly and the fan stacks. Between the basin
On the availability side, the loss of a cooling tower fan means
and the fan deck is the frame and support structure. The frame
reduced heat extraction capacity, which often results in a loss
is enclosed with a wood or fiberglass casing at each end with
of production. If a fan suffers a catastrophic failure, availability is
louvered sides to allow air entry. The cooling section of the tower
curtailed while expensive repairs are completed. A catastrophic
contains the fill. Where the fill is located within the tower depends
fan failure can cause significant structural damage to itself
on whether the tower is a cross-flow or counter-flow design. The
and the surrounding area.
bottom of a cooling tower consists of a concrete basin where
At present, many users rely on the vibration switch as the the cold water is collected after passing through the tower.
device that hopefully will minimize tower damage once a
Above the fill area is the hot water distribution system. The method
vibration-causing event occurs. This is an acceptable solution
of distributing the hot water to the fill is also dependent on tower
in most cases assuming the switch performs its job when the
design. The distribution system will be either a shallow pan-shape
time comes.
basin, located along the deck, that drops water over the fill, or it

15
application note
will be a system of spray nozzles mounted inside the frame below
the fan stacks. Drift eliminators are located above the fill, and
7.2 The cooling tower
just below the fan stack. Drift eliminators prevent water droplets mechanical system
(unevaporated water) from escaping through the fan stack. As mentioned earlier, the larger field-erected towers use
Cooling towers are divided into sections called cells. The cell is the axial type fans to move air through the tower. The axial fans
smallest tower subdivision that can function as an independent are part of a fan mechanical system consisting of an electric
unit with regard to air and water flow. motor, drive shaft, couplings, gearbox, and mechanical support.
A fan stack surrounds the fan assembly. The fan stacks are
Each cell may have one or more fan stacks and one or more water
miniature versions of hyperbolic towers, which aid air
distributions systems.
movement through convection.
Types of Towers • Fans: Fan blades are made of aluminum, stainless steel,
Many factors determine the type, size, and shape of a cooling tower. plastic or fiberglass. The length varies from 5 to 20 feet.
The final choice is determined by many factors such as individual Fan blades are designed to move a maximum amount
user requirements, economic considerations, local weather of air with the least amount of power. Other design
patterns, and aesthetics. The two basic cooling tower designs in considerations include safety, noise abatement, erosion
use today are the natural draft tower and the induced-draft tower. resistance, chemical resistance, interchangeability (balance),
and UV resistance. Fan blades are fixed to a hub that
Natural Draft Towers maintains fan position and pitch. Typical fan tip speed is
Natural draft cooling towers rely on natural forces to move air 12,000 fps, but due to OSHA noise restrictions, tip speeds
through the cooling section of the tower. The most recognizable are sometimes lowered to around 11,000 fps.
example of the natural draft tower is the large hyperbolic tower • Motors: Motors usually are furnished in accordance with the
used by many nuclear power generation stations. Hyperbolic purchaser’s specification. Motors range from 50 to 200 hp,
towers work much like a chimney, where the air flow is induced and typically use anti-friction type bearings. Motors operate
by convection. at 1,800/1,500 rpm. Variable speed motors and motors that
Natural-draft cooling towers are best suited for large water can be operated at half speed are being used more often as
capacity requirements, where space is a limiting factor. Although process control requirements demand tighter control of the
simple in design and easy to maintain, the natural draft cooling cooling capacity. The motor is mounted on the same support
tower’s use is limited by its high initial cost. Most towers in use as the gearbox but outside the fan stack and away from the
today rely on fans to move air through the tower. wet cooling tower air stream.
• Drive shaft and couplings: Power is transmitted from
Mechanical Draft Towers the motor to the gearbox via a floating drive shaft. Drive
Mechanical draft towers rely on axial or centrifugal fans to move shafts are made from stainless steel or composite materials.
air through the cooling tower fill. Mechanical draft towers may be Composite shafts are becoming more popular because they
either forced or induced draft. Forced draft fans are used on smaller are lighter than steel and less prone to bowing. Composite
towers where there is more of a need to control the air flow (hence shafts can span 20 feet without the need of an intermediate
the temperature), and less of a need for high air exit velocities. support bearing. Couplings are typically the composite or steel
disk type design.
An induced draft fan has a high air exit velocity, which serves
to push hot, humid air away from the tower, preventing it from • Gear drives: The gear drive purpose is to reduce the speed
recirculating into the tower. Induced draft towers are typically from the motor to a speed required by the fan. Gear drives
larger in size and provide larger air and water flow capacity. also change horizontal rotation to a vertical direction. The
most common gear drive on a large cooling tower is the
Towers also are characterized by how air and water are brought
double-reduction, right-angle drive utilizing spiral bevel or
together. In a cross-flow tower, air is mixed with a downward flow
helical gears. Typical reduction ratio is 18 to 1. The 18-to-1
of water in a horizontal direction. Hot water is pumped to the top
ratio provides a fan rotational speed of 90 to 100 rpm.
of the tower into a basin that runs along the length of the tower.
Gear drive ratios below 10 to 1 can use a single reduction
Gravity feeds the water into the fill through small holes in the
gear. These are used on smaller towers with faster fan
bottom of the basin. The cross-flow design usually provides a low
speeds. Splash type lubrication is more common than
resistance to air flow, enabling the tower to pass more air for a
forced lubrication.
given amount of power when compared to the cross-flow design.
The motors and pumps that deliver water to the water
In a cross-flow tower, air enters the bottom of the tower and
distribution system are also part of the cooling tower’s
moves upward against the falling water. Hot water is distributed
mechanical system.
to the fill with a pressurized spray system that runs through the
inside of the tower. This arrangement makes more efficient use
of the fill because it places the coldest water at the bottom to
the fill in contact with the incoming air, which is at the lowest
wet bulb temperature. Counterflow towers have greater air
resistance, and lower flow rates, than cross-flow towers.

16
 application note
7.3 Problems associated with • Bacteria control
• Corrosion control
cooling tower mechanical systems
• Wood deterioration
• Imbalance of the fan assembly
• Weather (wind, ice, sun)
• Imbalance of the drive shaft assembly
• Improper water loading
• Misalignment between motor and gearbox
• Drift escape
• Drive shaft bow.
Note: Drive shaft bow usually happens to steel or • Plume control.
aluminum shafts that have been sitting idle. In the Note: Plumes are the visible water vapor clouds that
daytime, the sun will heat one side of the shaft, are discharged from the fan stack under certain weather
causing a bow. This can cause high vibration if the conditions. The plumes are pure water vapor and are not
fan is started with a bowed shaft. Many users are harmful to the environment. However, these very noticeable
installing composite shafts that resist bowing. plumes are perceived by the public as pollution. Cooling tower
users take measures to abate the plume whenever possible
• Coupling failure
to maintain public relations.
• Loose gearbox mount.
• Rain/precipitation
Note: Corrosion of fasteners holding the gearbox
to the mechanical support are the main cause of • Noise
this condition.
Fin fan operation and description
• Loose fan-to-hub hardware
Fin fans do not use the evaporation of water to provide cooling.
• Loose motor mount Fin fans consist of several bundles of finned tube heat exchangers
mounted in a fabricated metal box. Fin fans operate on much
Fan assembly related problems the same principal as the condenser unit of an air conditioning
• Loose hub hardware system. Air is moved across the heat exchanger with a motor-driven
• Blade pitch change. induced draft or with a forced draft fan. On an induced draft
Note: Blade pitch change or irregularities will cause fin fan, the fan assembly is mounted above the finned tubes.
a 1X vibration component. This condition is similar Induced draft units minimize warm air recirculation and provide
to a balance problem. more precise process temperature control. Forced draft units
operate with the fans below the tube bundles, and are better
• Fan blade-to-fan stack rub suited for higher inlet process temperatures because the fan
• Fan blade erosion assembly is not in the hot air path.
• Fan auto-rotation (wind milling effect) The fin fan mechanical system consists of a motor-driven
axial flow, propeller type fan. V-belts transmit the power
• Gearbox bearing wear
from the motor to the fan. The fan rotational speeds range from
• Gearbox gear wear 200 to 400 rpm. In some cases, a small right angle gear speed
• Gearbox lubrication failure reducer is used in place of the belts. The method used is
determined by user preference. The belt system costs less
• Oil temperature but, the gear drive system is more reliable. The motor and fan
• Water ingression assembly are mounted to a common support channel that runs
across the structure’s mid-section. Fin fans are used as single,
• Motor bearing failure
standalone units, or bolted together in groups of two or three.
• Motor temperature problems
Fin fans are used to cool fluids other than water. They are
Non-mechanical cooling tower problems used mostly for cooling process liquids in the refining and
petrochemical industries. They are much smaller and easier
• Water treatment to install than cooling towers.
• Blow down disposal.
Note: Since the operation of a cooling tower depends
on evaporation as the principal means of heat dissipation,
chemicals present in the water will be concentrated.
Blow down is cooling tower water that is discharged
from the system to control concentration of salts, water
treatment compounds, wood treatment chemicals, or other
impurities in the circulating water. These compounds are
used to maintain water quality, or are presented as dissolved
solids in the makeup water.

17
application note
7.4 Observations
Changing Attitudes:
Users of cooling towers and fin fans are willing to invest dollars
to improve their fan monitoring systems. There are several reasons
for this, some of which have been discussed earlier. The main
reasons are:
• The current solution does not work since unanticipated
failures continue to occur.
• Users are becoming more knowledgeable in vibration
measurements, and demand better performance.
• The pressure to reduce operating and maintenance
costs makes false trips and missed trips intolerable.
Reliability is of utmost importance.
• Downsizing is reducing maintenance staff headcount,
increasing the chance that cooling towers and fin fans
will be neglected.
• Users are realizing the potential danger a fan failure
could pose to humans, thus increasing the awareness
of the need for a warning of impending failure.

18
application note

19
 © 2015 General Electric Company. All rights reserved. The information provided in this guideline
is subject to change without notice. Best practices and recommendations herein are applicable to
most cooling tower and fin fan installations. This guideline is not intended to replace or supersede
any manufacturer or OEM guidelines concerning proper installation and operation of their
GE Oil & Gas equipment.

1631 Bently Parkway South *Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric
Company. The GE brand, GE logo, Bently Nevada, System 1, Keyphasor, Proximitor, Velomitor,
Minden, NV 89423 RulePaks, Bently PERFORMANCE SE, ADRE, SPEEDTRONIC, Mark, Scout 100, Scout 140, vbOnline,
and SmartSignal are trademarks of General Electric Company.
24/7 customer support: +1 (775) 215-1818
geoilandgas.com/ GEA32335 (1/2016)