Conductivity sensors, available as an optimal addition to some process cooling units, play a vital role in monitoring the cooling water’s conductivity. This measurement is critical as it helps to determine the concentration of dissolved solids, like minerals and salts, which can significantly influence the system’s efficiency and longevity. These sensors operate using two electrodes immersed in the water. An alternating electrical current is applied, and the sensor measures the water’s electrical conductivity between the electrodes. Since conductivity is directly proportional to the concentration of dissolved solids, these readings are crucial for maintaining the health of the cooling system.

The data from conductivity sensors are instrumental in detecting issues such as fouling or scaling on heat exchangers. High concentrations of dissolved solids can lead to scaling, which diminishes efficiency and may cause equipment failure. Regular monitoring of water conductivity allows for early detection of such problems, enabling timely corrective actions that prevent equipment damage. Benefits of using conductivity sensors include precise monitoring for better management of dissolved solids, improved system efficiency, and early detection of potential issues. These sensors can also be integrated into automated control systems for continuous monitoring, optimising resource use and reducing human error. Additionally, they are generally easy to install and maintain, offering durability in various application environments.

However, there are some considerations when using conductivity sensors. They have a limited measurement range and may not be suitable for extremely high or low conductivity levels. These sensors are sensitive to temperature changes, which can affect measurement accuracy, though temperature compensation is typically used to mitigate this issue. Sensor fouling by particulates or contaminants may necessitate regular cleaning, and accuracy over time requires periodic calibration, which can be time-consuming. Moreover, the cost of high-precision conductivity sensors might be a barrier for smaller operations. Despite these challenges, when properly understood and managed, conductivity sensors are a valuable tool for process cooling equipment, offering crucial insights to maintain system health and efficiency.