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Cooling Towers

Cooling tower monitoring example

Concept for water hardness monitoring in cooling towers and other industrial applications

1    Pre-filter
2    Softening system
  Control Softmaster MMP1
4    Hardness monitoring Testomat® 2000/ECO
5    Chlorine monitoring Testomat® 2000 CLT/F
6    Bromine monitoring Testomat® 2000 Br

  Phosphate monitoring Testomat® 2000 PO4
8    Polymer monitoring Testomat® 2000 Polymer
9    Control of biocide dosing MultiControl CT
10    Conductivity probe
11    Motor valve
12    Plate heat exchanger

13    Biocide
14    Polymer
15    Phosphate
16    Bromine
17    Chlorine

Control and monitoring of recooling plants


Cooling water controlling and monitoring are indispensable components of advanced energy and

hygiene-compliant operation of cooling towers. 

What is the responsibility of the plant operator?

Industrial cooling systems rapidly dissipate excess heat from production processes and buildings. Despite economic and hygienic enhancements in recent years, malfunctions due to deposits and corrosion is are still a concern. Hygienic issues like legionella often spread swiftly in the system.

Prompt action remains crucial for operators of evaporative cooling systems to prevent mineral-based, corrosive, and biological accumulations like legionella and pseudomonads. Plant operators are urged to acquaint themselves with as disregarding these operator duties may result in legal consequences. Ensuring trouble-free, economical, and hygienic cooling tower operation requires continuous water monitoring and system conditioning.

What are the main focuses of monitoring?

In cooling systems – open, semi-open, or closed loop – evaporation is inevitable, elevating levels of salt concentrations in circulating water. Salt and mineral levels trigger limescale accumulation, corrosion, and mineral deposits within cooling towers and circulating water systems. This particularly affects drip collectors, trickling filters, distribution channels, and heat exchangers. The issue is exacerbated by biological challenges, including algae and biofilm formation from supply water and ambient air.

Remarkably, biofilms and mineral deposits like calcium or silicate have comparable energy impacts. A 1 mm biofilm layer or mineral deposit leads to a 30% loss in efficiency, translating to up to 12% increased energy costs.

In conclusion, a monitored online cooling tower system operates hygienically, efficiently and reduces malfunction.

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