PREFERRED CIRCULATING WATER CONDITION LIMITS FOR

GALVANIZED STEEL COOLING TOWERS

NOTE: Biological treatment and control of Legionella and other potentially health-threatening bacteria is essential.
Consult a competent water treatment expert or service company.

Startup
To prevent white rust, galvanized steel cooling towers should ideally be initially operated with water of pH
between 6.5 and 8.0, and with hardness and alkalinity values between 100 - 300 ppm (as CaCO3) for at
least 8 weeks. As an alternate, other acceptable water pretreatment methods may be considered.
Services of a competent water treatment specialist is recommended.
Once passivation of galvanized surfaces is achieved, the guidelines above can be relaxed.
Normal Tower Operation
pH 6.5 to 8.0
Temperature 125° F (51.7° C) maximum
Langelier Saturation Index 0.0 to 1.0
M-Alkalinity 100 to 500 ppm as CaCO3
Silica 150 ppm as SiO2 maximum
Iron 3 ppm maximum
Manganese 0.1 ppm maximum
Sulfides 1 ppm maximum for metal alloys. See below for further limits.
Chlorine 1 ppm free residual intermittently (shock), or 0.4 ppm continuously
maximum.
Organic solvents These can attack plastics and promote bio-growth. Trace amounts
(e.g., <50 ppm) may be acceptable.
TDS 1500 ppm maximum
Individual Ions: RANGE:
Cations: Calcium 50 - 500 ppm as CaCO3
Magnesium Depends on pH and Silica level
Sodium No limit
Anions: Chlorides 500 ppm as NaCl (300 ppm as Cl-) maximum
Sulfates 250 ppm as SO4 maximum
Nitrates 300 ppm as NO3 (bacteria nutrient) maximum

To avoid corrosion, the atmosphere surrounding the tower should be no worse than “moderate industrial”,
where rainfall and fog are no more than slightly acid, and they do not contain significant chlorides or hydrogen
sulfide (H2S).

Biological/Bacteria and Total Suspended Solids

Bacteria counts listed below relate to maintaining fill thermal efficiency only.
Biocidal treatment is required for all cooling tower installations. (see NOTE above).

Fill Type Aerobic Bacteria Total Suspended Oil and Sulfides

Standard Plate Count Solids (TSS) Grease*

MX75 100,000 CFU/ml < 50 ppm 1 ppm 1.0 ppm

10,000 CFU/ml < 150 ppm
MC47 10,000 CFU/ml < 25 ppm 1 ppm 0.5 ppm
* Any amount of oil or grease is likely to adversely affect thermal performance.

Miscellaneous Solids and Nutrients

For film fill, avoid fibrous, oily, greasy, fatty, or tarry materials which can plug fill, and avoid nutrients such as
glycols, alcohols, and sugars which promote bacterial growth.

NOTE: In general, do not use film fill in Steel Plants, Pulp & Paper Mills, Food Processing Operations, or similar
applications unless leaks and contamination by airborne or waterborne particulates, oil, or fibers are extremely unlikely.
If film fill is used, biological-growth control must be stringent and diligent.
WTRGALVY.doc Rev. 3, 4/5/01 KPM/RWP/MFP Rev. 2, 9/22/97 KPM/RWP/MFP