What is Process Cooling Water (PWC) and Why It's Critical in Businesses

In the world of industrial operations, heat is an unavoidable byproduct. Whether it’s generated by heavy machinery, chemical reactions, or electrical systems, this heat must be efficiently managed to ensure safety, performance, and longevity. One of the most reliable and widely used methods for removing unwanted heat is cooling water.

What Exactly is Process Cooling/Chilled Water (PCW)?

Process Cooling/Chilled Water refers to water that is used to absorb and remove excess heat from industrial equipment, processes, or environments. It functions as a heat transfer medium, carrying heat away from machinery or systems and either releasing it (via cooling towers or heat exchangers) or being discharged.

Data Centres	Food Factories	Petrochemical Plants	Electronics Manufacturing	Commercial Buildings (HVAC systems)
To prevent overheating of servers and maintain system performance.	To cool down heated products and keep fermenters within optimal range.	To maintain precise temperatures in chemical reactions and controlling of thermal risk	To keep machinery at stable temperature (Prevents damage to components)	To ensure consistent indoor air temperature and humidity.

There are usually 2 types of cooling water systems:

• Open-loop (cooling towers): Exposed to air and more prone to biological growth.

• Closed-loop: Less contamination risk, but scaling and corrosion still occur.

Common Problems Faced in Process Cooling/Chilled Water

While effective, cooling water systems face several challenges. In Singapore’s humid climate, urban air pollution, and high mineral content in some water sources make cooling water systems especially vulnerable.

Here are common issues faced by local facilities:

Root Cause of Process Cooling/Chilled Water (PCW) Problems	What Happens
Scaling	Mineral deposits can clog equipment and reduce heat transfer.
Corrosion	pH imbalance (Acidic) or oxygen presence can damage pipes and reduce system efficiency.
Biofouling	Warm stagnant water becomes a breeding ground for bacteria growth which can block water flow and triggers health and safety risk.

🏢 Under Singapore’s BCA guidelines, cooling towers must be maintained regularly and free of biological contamination, with monthly checks on microbial content.

Which Parameters Should You Monitor?

Parameter	Why It’s Important
pH Level	Low pH (<7): Promotes Corrosion High pH (>9): Promotes scaling Target range: 7.5 - 8.5 (may vary based on system type and treatment)
Conductivity (Total Dissolved Solids (TDS))	High conductivity = high scaling and corrosion potential.
ORP	Provide real time indication of biocide activity ORP < 600 mV may allow bacteria or algae to grow ORP > 800 mV may be corrosive to system metals
Chlorine	Maintains microbial control and prevent biofilm formation.
Hardness	Prevents scale buildup on heat transfer surfaces.

The Sustainability Angle

With increasing attention on sustainable industrial practices, managing cooling water efficiently is more important than ever. Companies are adopting greener cooling technologies, recycling water where possible, and investing in real-time water quality monitoring systems to optimize water usage and reduce thermal pollution.

Click HERE to learn more about Water Quality Monitoring for Industry Water.

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