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The True Cost of Inaccurate Moisture Measurement


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Inaccurate moisture readings can lead to significant issues like corrosion, clogs, and operational risks. In this blog post, we explore the impact of these inaccuracies, dissect the limitations of traditional analyzers, and examine how pioneering technology like CEIRS™ can mitigate these problems.

The Problems with Inaccurate Measurements:

Traditional moisture measurement instruments, including Aluminum Oxide sensors, possess limitations. These devices are prone to contamination issues and exhibit slow responses, resulting in unreliable readings. These inaccuracies might not look significant initially but will incur substantial costs over time, increasing maintenance and repair expenses. Here's a closer look at potential setbacks:

1. Corrosion: 

Excessive moisture content can accelerate corrosion, causing damage to pipe walls and essential components, ultimately leading to failures or ruptures.

2. Hydrate Formation: 

Elevated moisture levels can facilitate hydrate formation, which poses serious risks by potentially obstructing pipes and causing operational hazards.

3. Liquid Water Formation: 

Liquid water is formed when the pipe temperature falls below the water dew point of the gas.The presence of liquid water due to high moisture levels escalates the risk of corrosion and hydrate formation. Additionally, it tends to accumulate at pipe's lowest points, causing blockages.

4. Activation of Bacterial Spores: 

Moist environments encourage the growth of certain bacteria, accelerating corrosion rates and contributing to structural degradation.

5. Errors in Measurement: 

Excessive moisture can skew the accuracy of other critical gas-quality parameters, affecting the reliability of overall gas analysis.

Standards and Innovative Solutions:

Almost all the problems caused by water vapor are exasperated when the water dew point is high enough to create liquid water.  This happens when the water dew point is above the ambient temperature of the gas and the surfaces which gas comes into contact with.

Accurate moisture measurement is therefore imperative. ZEGAZ Instruments CEIRS™ (Chilled-mirror Evanescent IR Spectroscopy) technology utilizes infrared light for precise dew point measurements, within the limits of 0.5 centigrade error. Our analyzers are able to distinguish between various moisture types and offer resistance to contaminants.

CEIRS™ Technology: Advancing Accuracy

As we’ve discussed the advancement in Dew Point analyzers before, the chilled-mirror principle forms the basis of dew point analysis. During this process, a surface is cooled until condensation occurs. While traditional chilled-mirror methods often struggle to differentiate between moisture and hydrocarbon dew points, CEIRS™ overcomes this limitation by employing spectral analysis , providing unambiguous measurements.  CEIRS™ technology represents a significant advancement in dew point analysis by precisely detecting moisture and hydrocarbon dew points, setting new standards in reliable moisture analysis for gas measurements.

Furthermore, CEIRS(™) allows for measurement of the dew point at process (pipeline) pressure.  Almost all other methods (such as TDLAS and capacitance sensors) require pressure regulation down to near-atmospheric pressure.  Pressure regulation often causes changes to the composition of the gas, particularly the moisture content.  By eliminating the need for pressure regulation, CEIRS(™) technology elevates the levels of accuracy in moisture measurements.

Conclusion: Choose Carefully, Avoid Risks

In summary, accurate moisture measurement is pivotal in averting corrosion, hydrate formation, and bacterial growth. Traditional analyzers struggle with accurate dew point distinctions, leading to potential inaccuracies. CEIRS™ technology, grounded in the chilled-mirror principle, offers a breakthrough by precisely detecting moisture and hydrocarbon dew points. Opting for advanced technology like CEIRS™ ensures reliable gas analysis, mitigating risks posed by inaccuracies in industrial settings.


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