Power Industry Vibration Sensors

Improving Reliability in Power Generation with Cooling Tower Vibration Monitoring

In the power generation industry, cooling towers play a critical role in maintaining efficient and safe operation of turbines, generators, and auxiliary systems.

Failure of cooling tower components can result in reduced output, forced outages, and costly unplanned maintenance.

At Hansford Sensors we provide robust cooling tower vibration sensors and monitoring solutions designed to help power operators detect mechanical issues early and maintain reliable plant performance.

By monitoring vibration levels on key cooling tower components, maintenance teams can identify developing faults before failure occurs, supporting predictive maintenance strategies and maximising plant productivity.

Key Applications in Power Industry Cooling Towers

Hansford Sensors’ vibration sensors are widely used across cooling towers and associated power plant equipment, monitoring critical rotating assets such as:

• Cooling Tower Fans – Detecting imbalance, misalignment, and blade defects that can lead to excessive vibration and structural damage.
• Fan Drive Gearboxes – Monitoring bearing condition and gear mesh integrity to prevent failures.
• Motors – Identifying bearing wear, misalignment, and electrical-related vibration issues in fan and auxiliary motors.
• Shafts & Couplings – Monitoring for misalignment and mechanical looseness that can accelerate component wear.
• Pumps & Auxiliary Equipment – Ensuring reliable operation of circulating and cooling water systems.

Vibration Monitoring Solutions

Hansford Sensors offers a comprehensive range of cooling tower vibration sensors and monitoring solutions suitable for both online and offline condition monitoring in power generation environments:

• AC Accelerometers (e.g. HS-100 Series) – High-sensitivity sensors ideal for detailed vibration analysis and early detection of bearing and mechanical faults.
• 4–20mA Vibration Sensors (e.g. HS-420 Series) – Scaled output sensors designed for continuous monitoring and integration with plant PLC, DCS, and control systems.
• Waterproof Vibration Sensors – Sealed accelerometers suitable for wet, humid, and outdoor cooling tower environments.
• Enclosures & Junction Boxes (HS-JE & HS-SE Series) – Robust industrial enclosures available in stainless steel, polycarbonate, or mild steel to protect connections and ensure reliable signal integrity.

These vibration monitoring solutions enable power plant operators to trend equipment condition, plan maintenance effectively, and reduce the risk of unexpected cooling tower failures.

Designed for Demanding Power Generation Environments

Hansford Sensors’ cooling tower vibration sensors are engineered to perform reliably in challenging power industry conditions, including high humidity, temperature variations, constant vibration, and outdoor exposure.

With stainless steel construction, high ingress protection, and proven durability, they deliver consistent and accurate vibration data over long operating lifetimes.

From conventional thermal power stations to nuclear and renewable energy facilities, Hansford Sensors’ vibration monitoring solutions help power operators protect critical cooling infrastructure and maintain efficient, uninterrupted generation.