As a manufacturing facility operator or manager, you’ve likely experienced the frustrations of unplanned downtime. System disruptions caused by manufacturing cooling tower problems can be costly to address. However, the risks can also be greater than cost and inconvenience.
For instance, lack of regular maintenance can even increase the risk of harmful biological growth, such as Legionella bacteria. What’s more, neglecting maintenance can increase your chances of noncompliance with regulations, resulting in penalties and fines.
Working with a reliable industrial water treatment company that can regularly service your cooling tower and other equipment is key to preventing contamination and noncompliance. Use this manufacturing cooling tower water treatment guide to learn the importance of customized chemical treatment plans.
The Fundamentals of Cooling Water Treatment
Your cooling tower water treatment system is essential for reducing temperatures and expelling heat outside. A cooling water tower system can have many components, which vary depending on your facility and your specific system configuration. Other factors that can influence the arrangement of your system components include:
Local regulations for discharge
The quality of your feed water
The type of cooling tower you have, such as closed loop or open circulating
The type of heat exchanger
Cycle of concentration
Circulatory water chemistry
Professional recommended quality treatments
The above factors can impact the overall performance of your system, including how each individual component functions.
Most cooling tower systems are comprised of the following components:
Microbiological growth: Biological contamination comes in many shapes and forms. The hot, humid environment of a cooling tower can act as a breeding ground for various bacteria, algae, fungi and viruses. Additionally, untreated microbiological deposits like algae can develop a slimy biofilm texture over time, known as fouling, which can obstruct heat transfer surfaces and break down equipment.
Corrosion: All water-handling systems with metal components have the potential for corrosion. If your cooling tower isn’t properly treated, the metal will start to degrade. Internal corrosion only gets worse with time, which can result in damaged equipment or leaks in your system.
Scale formation: Scaling is commonly caused by a buildup of dissolved solids in the cooling tower. This accumulation usually occurs in hard water, which often consists of high concentrations of calcium. Scaling can impair heat transfer efficiency and potentially block or damage components within the system.
Airborne contaminants: Dust, pollen, sand and dirt that get trapped in your cooling tower can reduce overall efficiency and cause corrosion, fouling, scale and biological growth. A contaminated water supply can increase the risk of bacterial growth through evaporated particles. For instance, Legionella bacteria can thrive on stagnant, biofilm-covered water and colonize your cooling tower system. Air particles containing this bacteria can make workers sick and potentially cause Legionnaires’ Disease, a severe form of the flu.
All of the above challenges can impact cooling tower regulatory compliance in manufacturing industries. For example, your facility is required to comply with local, national and industry-specific regulations to protect others from health or safety risks, including controlling the growth and spread of Legionella. Other cooling tower regulations may include those set by:
Occupational Safety and Health Administration
Environmental Protection Agency
The American Society of Heating, Refrigerating and Air-Conditioning Engineers
The Cooling Technology Institute
The chemicals you use to control bacteria and algae growth in your cooling tower must also meet federal emissions standards. Relying on professionals to maintain your cooling towers and other equipment may help you comply with health regulations.
Step-by-Step Water Treatment Process
The water treatment process your facility needs will depend on the system’s design and layout. Here are some manufacturing cooling tower solutions you can expect:
Initial assessment: An inspection and assessment of your existing system is essential to evaluate your water quality and system needs.
Clarification: To make additional treatment steps more effective, sediment, particles and oils must be removed from the water. This process is known as clarification.
Filtration: The next step in the treatment process is filtration, which involves installing filters to remove suspended particles and solids early before the debris reaches sensitive equipment. Filtration can also minimize the risk of bacterial growth, corrosion and scaling and enhance water quality.
Ion exchange and softening: While it’s not always needed, your cooling tower water may require ion exchange and softening to remove hardness and clean minerals from the water.
Chemical treatment: If acidity or microorganisms are present at this stage, you may require water treatment services to add chemicals. Corrosion and scale inhibitor chemicals can minimize biofilms, protect metal components and prevent the growth of contaminants.
Automated monitoring: To prevent cooling tower system issues down the line, installing monitoring equipment is important. Contact headwater meters, conductivity controllers, biocide timers and pH probes are some examples of advanced equipment needed to streamline water quality monitoring.
Best Practices for Ongoing Cooling Tower Maintenance
Like any essential piece of equipment, your cooling tower system requires regular checks and inspections to spot issues early and maintain optimal conditions. Here are a few tips to keep in mind:
Routine inspections: Regular checkups can help you identify unusual issues in your cooling tower and allow you to respond with efficient repairs. Your inspections should generally include assessing fan operations, pressure gauges, water temperature, water level, chemical feeders, filters and pH control systems.
Water quality testing: Routine water quality testing is important to determine if improved filtration or water treatment systems are necessary at your facility. This testing can help you identify conductivity, pH levels and the amount of dissolved solids in the water.
System audits: A cooling tower system audit is a more intensive form of routine inspection. A team of experts will typically conduct these audits to identify operational risks and help you save money by conserving water and energy.
Staff training: Education is a powerful tool in keeping your workers and occupants safe during operations. It’s critical to ensure all personnel are trained and knowledgeable about water treatment protocols and understand their responsibility to inspect and report signs of corrosion or damage.
Contact Chardon Laboratories for Customized Solutions
Excessive time and effort spent repairing damaged components or trying to control bacterial growth in your cooling tower can hinder your business operations.
At Chardon Labs, we know how important it is for your equipment to be at peak performance at all times. We also recognize that cooling towers and water systems have many moving parts that need constant monitoring. That’s why we offer expert consultations for hvac, manufacturing, and many other industries that require ongoing maintenance.
Our ISO 9000-certified technicians are highly trained and can create a customized chemical treatment plan to fit your specific needs. Contact us today to learn about our optimized services for manufacturing cooling towers.
Matt Welsh
Matt Welsh is the Vice President and Water Consultant at Chardon Labs. He helps consult a wide range of customers utilizing various methods of water treatment, from chemical to chemical-free approaches, large and small applications, and across a wide range of geographical influences. With 20 years of water treatment experience, including a wide range of troubleshooting and service in potable water and non-potable HVAC and industrial applications, he is an expert in water treatment chemistry for cooling towers, boilers, and closed-loop systems.
