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Water-Cooled Condenser Tube Fouling (ΔT >5°C)

Likely causes

Scale (calcium carbonate) deposit in cooling water — poor cooling tower water treatment

Check: Measure cooling water supply/return ΔT (supply 32°C vs return >37°C) — plan tube cleaning immediately if ΔT >5°C. Check water quality: pH 7.5–8.5, conductivity ≤1,500 μS/cm, calcium hardness ≤200 mg/L

What to do: Brush cleaning (possible while running) → severe cases: circulate 10% citric acid 2–4 hours → neutralize (soda ash) → rinse. Improve water treatment and adjust blowdown valve (concentration ratio within 3–4x)

Cooling water flow velocity below 0.9 m/s — slime/biofilm formation

Check: Verify flow rate with flow meter or ΔT — confirm within ±10% of design flow. Check Y-strainer differential pressure to identify clogging

What to do: Restore flow by cleaning Y-strainer → inspect cooling water pump impeller → apply biocide water treatment to suppress slime

Insufficient cooling tower blowdown — concentration ratio exceeded

Check: Measure cooling water electrical conductivity — concentration ratio excessive if >1,500 μS/cm. Check blowdown valve opening and automatic blowdown timer settings

What to do: Increase blowdown valve opening — adjust to keep concentration ratio within 3–4x. Recommend installing automatic blowdown system linked to conductivity measurement

Field tip

ΔT >5°C = suspect tube fouling immediately. Brush cleaning can be done while running — no shutdown required. Monthly water quality checks (pH, conductivity, hardness) are essential.

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