thermal science

Cooling Tower Water Quality

M A N AG E M E N T, T R E AT M E N T A N D SYST E M M O N I TO R I N G

While it is important to consider equipment concerns at all times, C = (E+D+B) / (D+B) where:
maintaining system water condition is equally important for keeping
C = cycles of concentration
the cooling processes at full capacity and continuing effective
E = evaporation, approximately gpm x °F range x 0.0008
operation of the cooling tower.
D = drift loss, approximately gpm x 0.0002
Consider the cooling tower, along with the other mechanical B = blowdown gpm
components, as the cooling system hardware, while the water
It is the open nature of these systems that determines the unique
flowing through the cooling tower is the system software.
water problems that they exhibit. Cooling towers concentrate
Water condition is not often thought of as a potential variable solids and the air contact in these open systems allows the buildup
over time. The cooling water essentially is invisible to the operator, of contaminants, organics, bacteria and their food sources in the
but when left unattended, water supports biological growth, circulating cooling water.
and corrodes or scales equipment. Proper ongoing treatment is
These unique evaporative water system problems — concentration
important to process operation and efficiency.
and air washing — must be dealt with or process disasters will
Cooling loops remove waste heat from the process and function follow. Water is both the static and dynamic basis for controlling
by allowing water to evaporate to the atmosphere. The evaporated such problems.
water must be replaced continuously by fresh make-up water.

Without a bleed stream, commonly known as blowdown, the

dissolved solids in the original system’s water volume, plus Poor Water Maintenance Illustrated
dissolved solids added by the make-up water, will accumulate in Poor water maintenance will create certain and predictable
the system until precipitation begins. Eventually an unbled system problems in open cooling loops. These problems are detailed
will fill with solid scale material. below:
To balance the incoming water solids, a small portion of the Scale formation: Scale formation is the creation of a precipitated
circulating water stream with its elevated solids level is removed solid. By coating heat exchange surfaces, this solid material
to drain. An equilibrium is then established between the added interferes with efficiency of the system’s heat exchange surface
water replacing evaporation and high solids water losses, drift and and also blocks water flow at the cooling tower’s basin or fill.
blowdown. Cooling-loop precipitates generally are calcium carbonate crystals.
The term cycles of concentration is defined as the resulting ratio In a few cases, these are calcium sulfate or silica solids.
of concentrated solids in the circulating water compared to that Scaling occurs because specific dissolved solids, in the case
in the fresh makeup. Calculation of cycles is performed using of calcium carbonate scale, namely calcium and bicarbonate
the following equation. Alternatively, the blowdown required to alkalinity, have exceeded their solubility limits and are forming
establish a given equilibrium-cycles level can be derived from this solids. Calcium carbonate crystals commonly precipitate on critical
equation:
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surfaces, like the heat exchanger tube interior walls. The scale Biological fouling: Water left unattended for any significant
thickens the barrier to heat transfer, thus reducing the efficiency of length of time will grow bacteria, fungi, algae and even protozoa.
the cooling system. Severe scaling is shown in Figure 1. This diversity of growth, allowing organisms to flourish in a
protected environment, results in well established and difficult-to-
remove biofilm.

This growth process and its attachment to system surfaces is called

biological fouling. This growth is considered by many to be the root
of most cooling-loop water treatment problems. Those problems
include heat transfer efficiency reduction, cooling tower fill fouling,
water flow blockages, microbiologically induced corrosion and
human health concerns.

All of these effects are dramatic and serious. Biological control

must, therefore, be a primary part of good water system control.
A picture of a biologically fouled cooling tower fill is shown in
Figure 3.

FIGURE 1 Scale thickens the barrier to heat transfer, thus

reducing the efficiency of the cooling system

Corrosion: Corrosion is the process of metal dissolution, usually by

oxidation, resulting in substantial material breakdown and premature
degradation of system equipment. The oxidation process, in a very
simplified form, is the movement of electrons from metal system
components into the water medium provided in wet systems and
subsequently to a corrosion product of substantially different form
than the original base material. This process degrades the metal,
reduces its strength, thickness, and in some extreme cases, creates
pits and then holes in the material. At some point in the corrosion
process, the metal can no longer do its job as a system component. FIGURE 3 Biological fouling is the root of most cooling-loop water
Corrosion, in general, and pitting corrosion, in particular, must be treatment problems, according to many experts
guarded against in order to ensure the long term integrity of the
cooling system. Extensive corrosion is shown in Figure 2. Water Management Strategies
There are a number of strategies for combating each of the problems
described above. One must evaluate the system components, the
available water and water management techniques available for a
given site to determine the best solution for a specific case. Below
are discussions of the control techniques for each problem area.

Preventing scale: To prevent buildup of mineral scales, the first

and most important choice is the operating water chemistry of the
cooling loop as determined by the inlet and outlet water volumes
from the system. An operator must choose this operating cycles
level, using the equation cited earlier in this article, before any
subsequent treatment choices can be made.

Practical tools for automating water removal from the system are
an instrument to measure circulating water conductivity, solids in
the water and a signaled solenoid valve to bleed the water system
when necessary. The conductivity set point is the most critical
factor in operating an open evaporative cooling loop. Once the type
FIGURE 2 Corrosion, in general, and pitting corrosion, in of solids and their concentrations are known, an effective inhibitor
particular, must be guarded against in order to ensure selection can be made to ensure that deposition does not occur
the long-term integrity of the cooling system on vital heat exchange surfaces in the process equipment. One
can inhibit the most common scales by using sequestering agents
like HEDP (HydroxyEthylidene 1, 1 DiPhosphonicacid) and/or Finally, it is critical to provide a consistent and effective biocide
polymers like polyacrylate. addition to the system. In most cases this is a chlorine or bromine.
Because of regulatory pressures, one might consider other cooling
Other control strategies might include calcium reduction by water
water biocides like ozone or hydrogen peroxide. These compounds
softening or solubility modification by pH reduction.
are very effective biocides when properly applied and ozone can be
Preventing corrosion: Corrosion is prevented by a number of used as a stand-alone treatment in most HVAC cooling systems.
system choices and on-going prevention strategies. First, the bulk
In a conventional chemical treatment system, a service provider or
water chemistry at operating cycles of concentration as determined
self-administered water maintenance program consists of adding
in the scaling section will dramatically impact the corrosion rates
an oxidizing biocide and a combination scale and corrosion inhibitor
in a cooling system.
to the water system. One should monitor chemical treatment to
Once the system chemistry is known, one can then carefully choose determine the effectiveness of the program. This will prevent major
the system materials for the environment and for compatibility with operating problems in the system.
one another. Third, it is essential to keep the system clean. Deposits
In a number of cases, additional, specific additives may be
provide locations where bacteria can act to create non-standard
necessary to avoid unique problems presented by operating water
water conditions that dramatically increase the local corrosion rate.
chemistries and specific site issues. A modern pre-packaged
Therefore, the system must be substantially free from biological treatment pump and controller system is shown in Figure 4.
activity and largely clear of debris on surfaces, particularly in areas
where suspended solids will settle. Continuous filtration or regular
and thorough maintenance cleaning will accomplish this.

Finally, use corrosion inhibition or retardation products to protect

metal surfaces, especially the thin heat-exchange tubes where
corrosion problems can cost the system owner the most money.
Common yellow metals, such as copper and brass, usually are
protected with tolyltriazole, while steels are protected with ortho-
phosphate.

Biological growth: In order to continuously and effectively

operate a cooling system and establish sound biological control,
first eliminate nutrient sources that may add material to the system,
such as oil leaks, process fluid leaks and the like.

FIGURE 5 An example of a cooling-loop water treatment

schematic

Verification: How can an operator effectively track the

condition and treatment of cooling system water? A good water
treatment program requires vigilance and attention to system
control parameters. Primary monitoring targets typically include
conductivity, oxidation reduction potential (ORP), treatment
chemical concentration levels, general water analysis, and corrosion
coupons and probes. Several of these methods for verifying system
effectiveness are discussed below.

Manual method: The traditional water treatment model includes

evaluation, primarily consisting of monthly service visits that check
FIGURE 4 A modern packaged treatment pump and controller product inventories, corrosion coupons, probes, pumps and general
system is shown equipment maintenance. This type of program is personnel-
dependent and, by its very design, noncontinuous.

Second, limit the air-wash effect of the cooling tower, which Automated method: Newer water treatment systems use
naturally adds nutrients and bacteria to the system, by filtration for electronic monitoring to evaluate the reliability of treatment
removal of suspended solids and the bacteria that reside on them. delivery and the effectiveness of the treatment system in keeping
Effective filtration can be done either with centrifugal separators or the control parameters within specified limits. By using this type of
sand filters. A front-end strainer also is essential. control, a technician is dispatched only when problems requiring
on-site resolution are encountered.
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 thermal science

This labor efficiency increase may offset the additional equipment

cost in setting up automated sites. The effectiveness of treatment
systems can be evaluated every day by remote, trained technicians
using the automated system. This superior servicing model
probably will dominate over time in cooling-loop water treatment
and equipment monitoring.

An example of a cooling-loop water treatment schematic is shown

in Figure 5. This is the electronic monitor and adjustment interface
for a cooling loop. It includes a representation of the cooling tower,
the treatment side stream, the blow-down value and drain and the
water quality measurement probes.

In conclusion, cooling-loop water maintenance is essential to

efficient operation of the process served. Control of biological
growth is critical along with control of scaling and corrosion.

Water treatment is a complex undertaking with many parameters

to consider when properly treating a specific application. Consult
a qualified water services company to create the proper program
for your system.

SPX COOLING TECHNOLOGIES, INC.

7401 WEST 129 STREET TR-012 | ISSUED 10/2016
OVERLAND PARK, KS 66213 USA COPYRIGHT © 2016 SPX CORPORATION
913 664 7400 | [email protected] In the interest of technological progress, all products are subject to design

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