At IOThrifty, we work with customers from diverse industries—food processing, pharmaceuticals, HVAC, and more—who rely on accurate dew point measurements. Whether you’re monitoring moisture content in compressed air lines or ensuring environmental stability on a manufacturing floor, reliable dew point measurement devices, are essential to maintaining optimal process conditions.
However, measuring dew point isn’t always straightforward. Below, we’ll explore some of the most common problems users encounter when measuring dew point, along with practical tips on how to avoid them.
1. Sensor Drift Over Time
The Problem:
Over the lifespan of a dew point sensor or dew point transmitter, minor inaccuracies can accumulate, commonly referred to as “sensor drift.” Factors like exposure to contaminants, harsh chemicals, or even normal wear and tear can lead to gradually inaccurate readings.
How to Avoid It:
- Regular Calibration: At IOThrifty, we recommend routine calibration of all dew point devices—meters, transmitters, and sensors. We have a lot of customers that ask - How often should I recalibrate my sensors? The analogy we generally give is - How often do you get a new pair of shoes? It depends on a lot of factors, like what kinds of activities are you doing in those shoes? You can read more about dew point sensor calibration in this post.
- High-Quality Components: Invest in dew point transmitters or sensors designed for stability and long-term reliability. This helps reduce the risk of drift over time.
IOThrifty Tip:
Compare current readings to historical data or a reference dew point meter to quickly identify if your transmitter or sensor has drifted beyond acceptable limits.
2. Contamination & Condensation Issues
The Problem:
Dew point measurements rely on a clean, unobstructed sensor element. In real-world conditions, oil, dust, or moisture overload can build up on dew point sensors, leading to skewed readings—or even sensor damage. Condensation itself can form on the sensor if ambient conditions fluctuate too quickly.
How to Avoid It:
- Pre-Filtration: Use filters upstream of your dew point transmitter or sensor to remove particulate and oil vapor.
- Proper Mounting Location: Install sensors where temperature and flow are stable, reducing the likelihood of condensation.
- Scheduled Maintenance: Inspect, clean, or replace filters at recommended intervals to keep dew point sensors functioning optimally.
IOThrifty Tip:
Many of our dew point transmitters like the RHT Climate WM and the RHT Climate DM come with protective housings or sensor shields to reduce contamination and ensure measurement accuracy even in harsh industrial settings.
3. Extreme Environmental Conditions
The Problem:
Industrial settings can present extreme temperatures, high humidity, or even corrosive environments. If a dew point transmitter isn’t rated for these conditions, its sensor may deliver inconsistent data—or fail prematurely.
How to Avoid It:
- Choose Environment-Specific Models: Ensure your dew point sensors or transmitters are rated for the temperature, pressure, and humidity ranges of your facility.
- Protective Enclosures: When monitoring dew point in corrosive or very humid areas, place the sensor in an enclosure that shields it from direct exposure while allowing accurate readings.
- Monitor Ambient Changes: Track ambient conditions around the sensor so you can spot potential stress factors like rapid temperature swings.
IOThrifty Tip:
If you’re unsure which dew point transmitter can withstand extreme conditions, our technical team can guide you to the right models.
4. Incorrect Sensor Placement
The Problem:
Accurate dew point measurement depends not only on the quality of the sensor but also on where and how the sensor is installed. Placing a dew point transmitter near a heat source or in an area with frequent airflow fluctuations can distort readings. In compressed air systems, measuring dew point too far from the dryer can result in an incomplete picture of system moisture levels.
How to Avoid It:
- Measure at Critical Points: Position the transmitter or sensor where dew point measurements are most representative—such as the outlet of a dryer in a compressed air system.
- Follow Manufacturer Guidelines: Some dew point sensors require a specific orientation or distance from walls or other equipment.
- System Flow Considerations: Understand your process flow to ensure you’re measuring the dew point in the most meaningful location.
IOThrifty Tip:
Our experienced support team can help you plan sensor placement based on system schematics. Proper placement often means fewer false alarms and more reliable data.
5. Neglecting Periodic Maintenance & Calibration
The Problem:
“Set it and forget it” might work for some equipment, but dew point measuring devices—like dew point meters, dew point transmitters, and dew point sensors—require periodic checks to ensure ongoing accuracy. Overlooking maintenance can lead to false readings and potentially costly process issues.
How to Avoid It:
- Establish a Maintenance Schedule: At IOThrifty, we encourage proactive upkeep. Log your sensor’s or transmitter’s calibration dates, and set reminders for the next service interval.
- Compare Data Points: Cross-check your dew point readings with a reliable reference or a second sensor, especially if you notice unexpected spikes or dips.
- Use Built-In Diagnostics: Many high-quality dew point transmitters have diagnostic features that alert you if readings go out of range or if calibration is needed sooner than scheduled.
IOThrifty Tip:
Routine maintenance not only ensures accurate dew point data but also prolongs the life of your sensors and transmitters—saving you money in the long run.
Wrapping Up
Accurate dew point measurement can be challenging, but it’s crucial for countless industrial applications, from compressed air systems to food processing. By understanding these common pitfalls and taking a proactive approach—through regular calibration, proper sensor placement, and environment-appropriate dew point transmitters and sensors—you’ll reap the benefits of consistent, trustworthy data.
At IOThrifty, our mission is to help you succeed. If you have questions about choosing the right dew point instrument for your environment or need technical support, don’t hesitate to contact us. Our range of dew point meters, dew point transmitters, and dew point sensors is designed to fit various budgets and use-cases without compromising on quality or performance.