Round Solutions Industrial Water Intelligence – Powered by IO-GATE

Cooling Water Monitoring

Executive Summary

Unplanned downtime in industrial cooling systems is oftencaused by scaling, corrosion, or improper dosing of treatment chemicals. The IO-GATEEdge Device, in combination with ifm sensors such as PM1718(pressure monitoring), AL2205 (analogue signal converter), DP2200(differential pressure sensor), SM4000 (flow sensor), and R1D100(temperature sensor), provides continuous and precise monitoring of all keyparameters — including flow, pressure, differential pressure, conductivity,and temperature.

Through real-time data processing and smart cloudconnectivity, operators can predict fouling, optimize dosing, and extendequipment lifetime. This transforms traditional water treatment into a data-drivenprocess that improves efficiency, reliability, and sustainability.

Industry Challenge

Cooling water systems are critical to production in pulp& paper, chemical, and steel industries. Poor water quality or lack ofcontinuous monitoring leads to scaling, reduced heat-exchange efficiency,and corrosion, resulting in costly maintenance and productioninterruptions.

Manual sampling and delayed laboratory analysis makereal-time optimization impossible. The industry needs a robust, automatedmonitoring solution with accurate sensor integration to provideactionable insights before problems cause downtime.

Solution Overview – IO-GATE Architecture

The IO-GATE Edge Device connects ifm processsensors directly to industrial networks, supporting interfaces such as Modbus,4–20 mA, IO-Link, and RS-485.
All incoming signals — for example from:

• SM4000     for flow rate
• PM1718     for system pressure
• DP2200     for filter differential pressure
• R1D100     for temperature
• AL2205     for signal conversion or analog integration —
      are locally normalized and processed by rule-based logic (e.g. “trigger     alarm if pressure < 2 bar or temperature > 60 °C”).

The processed data is securely transmitted to CumulocityIoT, Azure IoT Hub, or other platforms, where analytics dashboardsvisualize trends, alarms, and KPIs. Operators access these insights via webdashboards or mobile apps, enabling predictive maintenance and automaticalerts.

Even if cloud connectivity fails, IO-GATE continues localprocessing — ensuring maximum reliability.

Results and Benefits

Field deployments have demonstrated measurable operationalimprovements:

• Water     savings: up to 15 % through optimized blowdown cycles
• Energy     efficiency: 3–5 % gain from stable heat-exchange surfaces
• Chemical     reduction: 10–20 % less overdosing through real-time control
• Downtime     reduction: up to 8 hours less per month
• ROI:     typically achieved within 12 months

These results show the value of connecting precise ifmsensor data directly to decision-making. IO-GATE converts raw measurementsinto actionable insights — enabling immediate response before small anomaliesescalate.

Sustainability and Future Outlook

By integrating IO-GATE with ifm’s proven industrialsensors, companies enable data-driven water management aligned withsustainability goals. Reduced water and energy use, lower chemical waste, andextended equipment lifetime all contribute to a smaller environmentalfootprint and lower operating costs.

The same architecture can easily be expanded to boilersystems, wastewater treatment, or chemical storage monitoring,forming a unified Industrial Water Intelligence Network acrossfacilities.

Conclusion

Industrial Water Intelligence represents the nextstep toward smarter, cleaner, and more efficient operations.
With IO-GATE and ifm sensor technology, Round Solutions delivers a scalable,secure, and future-ready platform that moves industries from manualmonitoring to predictive control — maximizing uptime, cutting cost, andadvancing sustainability.
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Round Solutions – Industrial Water Intelligence
Powered by IO-GATE & ifm Sensor Technology
Smart Data for Smart Water.

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