Cooling Tower Thermal Performance Testing by EKG M&E Sdn Bhd
In the tropical environment of Kuala Lumpur and Selangor, a cooling tower’s "nameplate" capacity often differs from its "actual" field performance. Factors like infill scaling, poor airflow, and high ambient wet-bulb temperatures can cause a tower to underperform, forcing your Chiller to work harder. Thermal Performance Testing is a rigorous engineering audit used to determine the exact percentage of design capability your tower is currently delivering.
EKG M&E Sdn Bhd conducts performance evaluations following the industry-standard CTI ATC-105 (Cooling Technology Institute) protocols to verify your system's heat rejection health.
1. Key Metrics of the Thermal Audit
As an HVAC and Clean Air Specialist, we focus on the mathematical relationship between water flow, air temperature, and heat load.
A. The "Approach" and "Range"
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Cooling Range: The difference between the hot water entering the tower and the cold water leaving it. This tells us the total heat energy being removed.
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Approach: The difference between the cold water temperature and the ambient Wet-Bulb Temperature. This is the single best indicator of a tower's efficiency. A wider-than-design approach usually indicates fouled infill or insufficient airflow.
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Formula: Efficiency (%) = Range / (Range + Approach) x 100.
B. Tower Capability Percentage
This is the ultimate "pass/fail" metric. It represents the percentage of the design water flow that the tower is actually capable of cooling at design temperatures.
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100% Capability: The tower is performing exactly as promised.
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90% Capability: The tower can only handle 90% of its rated load; any more will cause the Chiller to run too hot.
2. The EKG M&E Testing Protocol (CTI ATC-105)
We utilize high-precision, calibrated instruments to ensure data accuracy within 0.1 degrees.
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Step 1: Load Stabilization: We ensure the system heat load is steady (typically between 90% and 110% of design) for at least one hour before taking measurements.
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Step 2: Data Acquisition: We simultaneously measure:
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Entering and Leaving Water Temperatures (using immersion sensors).
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Circulating Water Flow Rate (using ultrasonic flow meters or Pitot tube traverse).
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Ambient Wet-Bulb/Dry-Bulb Temperatures (using mechanically aspirated psychrometers).
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Fan Motor Power (to ensure the fan is pulling the correct air volume).
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Step 3: Performance Curve Mapping: We plot the test data against the manufacturer’s design curves to calculate the final capability percentage.
3. Why Conduct a Thermal Test?
| Objective | Benefit for Facility Managers |
| New Commissioning | Proves the contractor delivered 100% of the purchased capacity. |
| Energy Audit | Identifies if a "High Approach" is causing your Chiller to waste electricity. |
| Retrofit Validation | Confirms that new Infill or Fan Pitch adjustments actually improved cooling. |
| Troubleshooting | Solves "High Head Pressure" trips on Chillers during KL's afternoon peaks. |
Why Choose EKG M&E Sdn Bhd?
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Independent Verification: We provide unbiased, third-party testing to resolve disputes between building owners and equipment vendors.
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Root Cause Analysis: If a tower fails the test, we don't just provide a report—we identify the fix, whether it's a Gearbox Overhaul, Nozzle Cleaning, or VFD Optimization.
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Strategic Support: Based in Kuala Lumpur, we provide turnkey testing, structural repairs, and energy-saving retrofits for major commercial and industrial plants.
