From Manual to Automated: How TEC Transformed Cranfield University’s Cooling Tower Operations

From Manual to Automated: How TEC Transformed Cranfield University’s Cooling Tower Operations

When cooling tower dosing systems fail, the consequences extend far beyond inconvenience. For Cranfield University, one of the UK’s leading postgraduate institutions, a non-functional dosing system was forcing facilities staff into time-consuming manual chemical dosing routines.  

In this blog post, we explore how TEC’s water treatment experts transformed a challenging installation into a showcase of modern automated cooling tower management, delivering operational excellence while working within significant spatial constraints. 

The Challenge of Obsolete Infrastructure 

Even prestigious institutions like Cranfield University – ranked in the UK’s top ten for commercial research and consultancy – can face critical infrastructure challenges. Their aging cooling tower chemical dosing system had been out of service for an extended period, creating operational difficulties. 

Manual dosing isn’t just inefficient – it’s potentially dangerous. Without automated monitoring and adjustment capabilities, maintaining consistent chemical levels becomes a constant challenge 

The technical challenges were equally daunting. The plant room location offered minimal working space and poor lighting conditions, while the existing pipework configuration was completely unsuitable for modern automated systems. 

Engineering Excellence in Confined Spaces 

TEC’s approach to this challenge showcased the problem-solving capabilities that define professional water treatment installation. Rather than compromising on system capabilities due to space constraints, our Water Treatment Team designed a comprehensive solution that maximised functionality within the available area. 

The new system centred around an Intuition 6 controller – a state-of-the-art unit featuring an intuitive colour touchscreen that university staff found immediately accessible. Three precision dosing pumps, ORP and conductivity probes, automatic bleed functionality, and integrated flow sensors created a fully automated water treatment management system. 

The installation itself required innovative thinking. With conventional wall mounting impossible due to space limitations, TEC’s engineers constructed a custom metal frame system, securely anchored to both wall and floor. This solution provided a stable platform for the sophisticated equipment while maintaining easy access for future maintenance. 

Results That Speak for Themselves 

The transformation was immediate and comprehensive. Where manual dosing had previously required constant staff attention, the new automated system continuously monitors and adjusts chemical levels based on real-time water quality data. Inhibitor chemicals are dosed proportionally with makeup water, bleed cycles are automatically managed based on conductivity levels, and secondary biocide dosing operates on precise timer controls. 

Perhaps most importantly, the system has operated flawlessly since commissioning. University facilities management were particularly impressed with the professional installation quality – a testament to TEC’s commitment to excellence even in challenging environments where “no one will see” the finished work. 

The TEC Difference 

This project exemplifies TEC’s approach to water treatment challenges: comprehensive technical solutions delivered with precise attention to detail, regardless of installation complexity. Our 30 years of specialised experience enables us to transform even the most challenging situations into opportunities for operational improvement. 

Whether you’re managing aging infrastructure, space-constrained installations, or complex technical requirements, TEC’s water treatment expertise ensures your systems operate at peak efficiency while maintaining full regulatory compliance. 

Curious to learn more about this project? Read the full case study here to discover the complete technical details behind this successful cooling tower dosing system upgrade. 

Partner with Total Environmental Compliance 

The trusted water partner for hundreds of organisations, TEC brings 30 years of specialised experience to support your operations. Our team of qualified engineers and technicians provides comprehensive management solutions, from risk assessment and maintenance programmes to emergency response services. 

Get in touch with TEC today and discover how our expertise can protect your operations. Call us at 01536 650601 or email info@tecompliance.co.uk to schedule a consultation with our specialists.