Industrial sensor helps prevent condensate-related equipment issues

Emerson has launched its new AVENTICS DS1 dew point sensor, the only industrial sensor to monitor dew point, temperature, humidity levels and, compressed air quality and other non-corrosive gases in real-time from one device. The sensor can assist operators to detect and mitigate excess moisture in its early stages and prevent moisture-related equipment damage. By optimising air quality in this way, operators can better control processes, extend pneumatic component life, ensure regulatory compliance, and decrease maintenance and unplanned downtime.

Pneumatic systems deliver power to manufacturing processes across the plant floor in most industries, from pharmaceuticals and food and beverage to semiconductors and automobiles. Excess moisture in pneumatic systems can cause multiple issues, including corroded components, product inconsistency and erratic processes.

While most industrial sensors only monitor humidity, the new device provides precise dew point monitoring that allows manufacturers to continuously track critical values, address excess moisture and prevent its negative effects. For instance, moisture can affect process reliability by corroding components, washing the lubrication out of moving parts, and extending switching and reaction times.

Ideal air quality is also critical when compressed air comes in contact with consumer products such as pharmaceuticals or food. Condensate in compressed air can cause discolouration, texture inconsistency and bacterial growth. The device provides essential data that facilities require to maintain a stable dew point and protect product quality. If there are regulations regarding air quality, the device can help companies meet requirements and maintain compliance.

“By having greater certainty about compressed air quality and control over moisture levels in compressed air lines, manufacturers of all kinds can prevent a number of common condensate-related issues and their associated costs,” said Manuel Goerbert, product marketing manager of discrete sensors at Emerson. “The new AVENTICS DS1 dew point sensor allows operators to detect changes in air quality in real-time with a single device, so they can quickly make necessary adjustments to optimise production and increase overall process reliability.”

To support industrial digital transformation strategies, the DS1 dew point sensor easily integrates into existing systems, including the AVENTICS Series AS3 and AVENTICS Series 652 air preparation units, and connects to networks via Modbus TCP (PoE). One of the key advantages of an integrated dew point sensor is the ability to place the sensor – and track conditions – close to the process rather than where the compressed air is generated, which can be far from the process itself and have many different conditions.

The sensor element is condensation-resistant and supplies long-term, drift-proof performance. With fast response time, DS1 measurement values include pressure dewpoint, temperature, relative humidity, absolute humidity, moisture content, moisture content V/V, water vapour partial pressure and atmospheric dew point. The DS1 is also suited to other non-corrosive gases, including nitrogen, oxygen, argon, helium and sulphur hexafluoride.