Understanding the Role of AI in Predictive Cooling Tower Maintenance
- Suzanne Matulis
- Jul 24
- 3 min read
How AI Is Reshaping Cooling System Uptime
When most people think of artificial intelligence (AI), they picture self-driving cars or voice assistants—not industrial cooling towers. But behind the scenes, AI is making its mark in one of the most overlooked but essential parts of facility operations: predictive maintenance for cooling towers.
Gone are the days when maintenance teams had to rely solely on time-based schedules or reactive emergency calls. Today, solutions like Infinite Cooling’s TowerPulse™ are changing the game by using sensor data, AI, and physics-based models to anticipate problems before they cause costly breakdowns.
What Is Predictive Maintenance—and Why Does It Matter?
Traditional cooling tower maintenance usually falls into one of two categories:
Time-based: Clean or inspect every 6 or 12 months, regardless of need.
Reactive: Fix only when something breaks (often too late).
Predictive maintenance shifts the paradigm. It relies on real-time data from sensors—measuring things like water flow, fan speed, and thermal performance—to forecast when and where issues will occur. That means you can fix the problem before it affects production, increases energy use, or causes permanent damage.
The Technology Behind TowerPulse™
So how does it work?
TowerPulse™ combines three core components:
Wireless IoT Sensors: These track critical parameters like water flow, air velocity, temperature differentials, and energy consumption across your cooling tower cells.
AI Algorithms: TowerPulse™ uses machine learning models trained on industry-wide data and your own historical trends to detect patterns and anomalies.
Physics-Based Models: It doesn’t just look at numbers—it compares real-time performance to manufacturer specs using metrics like Cooling Tower Capability, developed by CTI.
Together, these components enable continuous retro-commissioning—not just once-a-year audits, but real-time health checks and optimization suggestions 24/7.
What Can AI Detect in a Cooling Tower?
Imminent Equipment Failure TowerPulse™ once spotted a faulty control algorithm that was causing repeated “hot starts” in a power plant’s cooling tower fans. Left unchecked, this would’ve led to gearbox failure and a six-figure repair bill.
Loss in Cooling Efficiency At a university central plant, airflow restrictions raised return water temps by 2.5°C, reducing chiller performance by 8%. TowerPulse™ flagged the issue, and the team adjusted their tower fan blade angles for an instant performance gain.
Water Treatment Degradation Through its NTU (Number of Transfer Units) metric, TowerPulse™ detected a drop in heat transfer efficiency at a power plant. This turned out to be biofouling linked to suboptimal chemical dosing—prompting a fix that increased turbine output by 1 MW.
Benefits Beyond Just Repairs
AI-enabled predictive maintenance offers wide-ranging benefits:
Benefit | Impact |
Fewer unplanned shutdowns | Prevent lost revenue and overtime labor |
Higher process efficiency | Avoid energy waste from undercooled chillers or turbines |
Longer equipment life | Reduce wear and tear by avoiding harsh conditions |
Targeted maintenance | Do what’s needed, when it’s needed—not based on a calendar |
Better ROI from CapEx | Continuous data helps justify upgrades like VFDs or new drift eliminators |
Why AI Matters for Sustainability, Too
Predictive cooling tower maintenance isn’t just a cost-saver—it’s also a sustainability enabler:
Reduced energy use = lower emissions
Less chemical overdosing = less environmental discharge
Better performance = more output with the same inputs
When paired with WaterPanel™, which recovers evaporated water from plumes, the result is a cooling system that’s smarter, cleaner, and more efficient.
Conclusion: From Reactive to Proactive
Cooling towers are often overlooked—but when they fail, they bring processes to a halt. AI-driven systems like TowerPulse™ offer a better way: one where your team acts before problems escalate, and where your cooling infrastructure becomes an active contributor to your facility’s bottom line.
Looking to bring predictive maintenance to your plant? Let’s talk. TowerPulse™ can help you make smarter decisions, extend asset life, and save thousands—sometimes millions—by getting ahead of issues, not chasing them.